Modelling of Material Removal Rate in EDM of Nonconductive ZrO2 Ceramic by Taguchi Method

2013 ◽  
Vol 393 ◽  
pp. 246-252 ◽  
Author(s):  
A. Sabur ◽  
Mohammad Yeakub Ali ◽  
M.A. Maleque
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Carbon Layer ◽  
Machining Process ◽  
Machined Surface ◽  
Pulse On Time ◽  
Pulse Off Time

Electro discharge machining (EDM) technique, a noncontact machining process, is applied for structuring nonconductive ZrO2 ceramic. A conductive layer of adhesive copper is applied on the workpiece surface to initiate the sparks. Kerosene is used as dielectric for creation of continuous conductive pyrolytic carbon layer on the machined surface. Experiments are conducted by varying the peak current (Ip), pulse-on time (Ton), pulse-off time (Toff) and gap voltage (Vg). Correlating these variables a mathematical model for material removal rate (MRR) is developed using Taguchi method. The optimized parametric conditions are determined for higher MRR through ANOVA and signal to noise (S/N) ratio analysis. The results showed that the Ip and Ton are the significant parameters of MRR in EDM for nonconductive ZrO2 ceramic. The model also showed that MRR increases with the increase of Ip and Ton, but the process is controlled by Ip as a whole.

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

scholarly journals Effect of Micro-EDM Parameters on Material Removal Rate of Nonconductive ZrO2 Ceramic

2013 ◽  
Vol 465-466 ◽  
pp. 1329-1333 ◽  
Author(s):  
Abdus Sabur ◽  
Abdul Moudood ◽  
Mohammad Yeakub Ali ◽  
Mohammad Abdul Maleque
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Carbon Layer ◽  
Machining Process ◽  
Machining Parameters ◽  
Micro Edm ◽  
Machined Surface ◽  
Electro Discharge Machining

Micro-electro discharge machining (micro-EDM) technique, an advanced noncontact machining process, is used for structuring of nonconductive ZrO2 ceramic. In this study copper foil as a conductive layer is adhered on the workpiece surface to initiate the sparks and kerosene is used as dielectric for creation of continuous conductive pyrolytic carbon layer on the machined surface. Voltage (V) and capacitance (C) are considered as the parameters to investigate the process capability of machining parameters in continuous micro-EDM of ZrO2. Different voltage pulses are studied to examine the causes of lower material removal rate (MRR) in micro-EDM of nonconductive ceramics. The results showed that in micro-EDM of ZrO2 MRR increases with the increase of voltage and capacitance initially, but decreases at higher values and no significant materials are removed at capacitances higher than 1nF.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics

2019 ◽  
Vol 233 (14) ◽  
pp. 2515-2530 ◽  
Author(s):  
R Rajeswari ◽  
MS Shunmugam
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Machining Process ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Pulse On Time

Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a consequential reduction in cycle time. Powder mix and ultrasonic assistance are employed in the electrical discharge machining process to create gap conditions favoring material removal. In the present work, experiments are carried out on hardened D3 die steel using full-factorial design based on three levels of voltage, current and pulse on time. The gap phenomena in graphite powder-mixed and ultrasonic-assisted rough electrical discharge machining are studied using a detailed analysis of pulse shapes and their characteristic trains. Two new parameters, namely, energy expended over a second ( E) and performance factor ( PF) denoting the ratio of energy associated with sparks to total discharge energy, bring out gap conditions effectively. In comparison with the conventional electrical discharge machining for the selected condition, it is seen that the graphite powder mixed in the dielectric enhances the material removal rate by 20.8% with E of 215 J and PF of 0.227, while these values are 179.8 J and 0.076 for ultrasonic-assisted electrical discharge machining with marginal reduction of 3.9%. Cross-sectional images of workpieces also reveal the influence of electrical discharge machining conditions on the machined surface. The proposed approach can be extended to different powder mix and ultrasonic conditions to identify condition favoring higher material removal.

Performance Measurement and Data Analysis of Material Removal Rate for Wire Cut Electro Discharge Machining Process

2011 ◽  
Vol 110-116 ◽  
pp. 1683-1690 ◽  
Author(s):  
Vishal Parashar ◽  
A. Rehman ◽  
J.L. Bhagoria
Keyword(s):  
Regression Analysis ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Performance Criteria ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing

In this paper, statistical and regression analysis of material removal rate using design of experiments is proposed for WEDM operations. Experimentation was planned as per Taguchi’s mixed orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, pulse OFF time, wire feed and dielectric flushing pressure. Stainless Steel grade 304L was selected as a work material to conduct the experiments. From experimental results, the material removal rate was determined for each machining performance criteria. Analysis of variance (ANOVA) technique was used to find out the variables affecting the material removal rate. Assumptions of ANOVA were discussed and carefully examined using analysis of residuals. Variation of the material removal rate with machining parameters was mathematically modeled by using the regression analysis method. The developed model was validated with a set of experimental data and appeared to be satisfactory. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method.

Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method

2015 ◽  
Vol 799-800 ◽  
pp. 343-350
Author(s):  
Rahul Shukla ◽  
Brajesh Kumar Lodhi
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Kerf Width ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

Effect of Gap Voltage and Pulse-On Time on Material Removal Rate for Electrical Discharge Machining of Al2O3

2015 ◽  
Vol 1115 ◽  
pp. 3-6 ◽  
Author(s):  
M.A. Moudood ◽  
Abdus Sabur ◽  
Mohammad Yeakub Ali ◽  
I.H. Jaafar
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Carbon Layer ◽  
Peak Current ◽  
Conductive Ceramics ◽  
Pulse On Time

Electrical discharge machining (EDM) is a non-conventional machining technique which can be used to machine non-conductive ceramics. This technique removes materials from the workpiece by thermal energy exerted from series of electrical sparks. Using copper foil as assisting electrode (AE), machining of Al2O3 is done successfully. In this investigation, experiments were performed to study the effect of gap voltage and pulse-on time on material removal rate (MRR) for EDM of Al2O3. The results showed that the lowest and the highest values of gap voltage were 12 V and 14 V, respectively, with a fixed peak current of 1.1 A and pulse-on time of 8 μs. Beyond these two voltage values, material cannot be removed due to insufficient pyrolytic carbon layer generation. Similarly, pulse-on time is varied from 6 μs to 8 μs when gap voltage is fixed at 14 V and peak current at 1.1 A. MRR, in this case, is increased almost 20 times from a lowest value of 0.006 mm3/min to a highest value of 0.119 mm3/min for the specified gap voltage and pulse-on time.

COMPARATIVE STUDY OF MATERIAL REMOVAL RATE AND TOOL WEAR RATE OF COPPER AND ALUMINIUM ON DIE SINKING EDM

2015 ◽  
Vol 77 (21) ◽  
Author(s):  
Maidin S. ◽  
H.H. El Grour ◽  
Seeying C.
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Work Piece ◽  
Small Depth ◽  
Pulse On Time ◽  
Pulse Off Time

The electrical discharge machining (EDM) is one of non - conventional machining process where the erosion of the work piece take place based on the thermal energy between the electrode and the work piece. Due to the widely used and its availability, copper and aluminium was used in this study. These two materials was machined using die sinking EDM to study the characteristics of each material using copper electrode. Few research has been conducted to study copper electrode to machined copper work piece and this was considered as a challenge in this research. More heat was generated and more time consumed was the reason behind machining small depth in this research. The important factors such as discharge current, voltage, pulse on time and pulse off time monitored and recorded to know how these factors effect on the Material Removal Rate (MRR) and Tool Wear Ratio (TWR) of the copper and aluminium work piece material. The experiments conducted under the designed full factorial procedure where pulse on-time and pulse current are used as the input parameters. It was found that material MRR increases with increase in current and pulse duration, but MRR is higher during machining of aluminum than that of copper. In term of TWR it is found that the TWR resulting of machining copper is lower than aluminium

Single Discharge Finite Element Simulation of EDM Process

2015 ◽  
Vol 14 (02) ◽  
pp. 75-89 ◽  
Author(s):  
Rohit Rajendran ◽  
S. P. Vendan
Keyword(s):  
Finite Element ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Workpiece Material ◽  
Machined Surface ◽  
Input Parameters ◽  
Pulse On Time ◽  
Aisi H13 Tool Steel

The energy distribution in the electric discharge machining process influences the material removal rate, relative wear ratio and the surface roughness of the machined surface and the effective energy is the part of energy which is distributed toward workpiece to be machined. The theoretical modeling of the process is based upon the heat transfer equations and one of the important parameter is fraction of energy transferred to the workpiece. The model first calculates the temperature distribution in the workpiece material using ANSYS Finite element coding and then volume removed due to single spark is estimated from the temperature profiles. Theoretical material removal rate at different input parameters are compared with the experimental results, making it possible to determine the portion of energy that enters AISI H13 tool steel workpiece. The effect of input parameters (discharge current, voltage, pulse on time) on temperature distributions along the radius and depth of the workpiece has been reported.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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