Performance Evaluation of Electrical Discharge Machining Die Sinking on Stainless Steel 316L Using Copper Impregnated Graphite

2014 ◽  
Vol 660 ◽  
pp. 48-54 ◽  
Author(s):  
Wahaizad Safiei ◽  
Safian Sharif ◽  
Ahmad Fairuz Mansor ◽  
Mohd Halimudin Mohd Isa
Keyword(s):  
Stainless Steel ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Time Range ◽  
Electrode Wear ◽  
Stainless Steel 316L ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This study presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of Electrical Discharge Machining (EDM) input parameters on characteristics of EDM process. The machining parameters include peak current, servo voltage, pulse ON time and pulse OFF time. The study was conducted using 2 levels of Full Factorial Method in Design of Experiments. The design expert software employed to perform all the data analysis for Full Factorial and Central Composite Design (CCD) experiments. This study evaluates the machining performance of the Stainless Steel 316L using Sodick EDM linear motor series AM3L which employed Copper impregnated graphite diameter 7.0 mm as the tool electrode. The response variables are material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR) and dimensional accuracy. The result shows that the peak current was the most significant factors to all variable responses. The servo voltage does not have significant effects to the machining responses in RSM. Higher current produced higher MRR, EWR, SR and Dimensional Accuracy. Maximum MRR was obtained at peak current range from 27amp to 38amp, pulse on time range from 120μs to 145μs and 60μs of pulse off time. Maximum EWR was obtained at peak current range from 27amp to 37amp, pulse on time range from 140μs to 160μs and 60μs of pulse off time. High probably, the minimum EWR only can be obtained if peak current parameter sets greater than 45amp. Lower dimensional accuracy and SR obtain at 5amp of pulse on time. Higher pulse off time produced lower MRR and EWR.Keywords: EDM Die sinking, Stainless Steel 316L, Copper Impregnated Graphite Electrode, Response Surface Methodology, Surface Roughness, Material Removal Rate, Electrode Wear Rate, Dimensional Accuracy

The Effect of EDM Die-Sinking Parameters on Machining Characteristics in Aluminum Alloy Machining

2015 ◽  
Vol 761 ◽  
pp. 303-307 ◽  
Author(s):  
Laily Suraya ◽  
M.A. Ali ◽  
N.I.S. Hussein ◽  
Mohd Razali Muhamad ◽  
Manshoor Bukhari ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Design Matrix ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electrode Tool ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Machining Characteristics

The effect of machining parameters on machining characteristics for aluminium alloy LM6 (Al-Sil2) in Electrical Discharge Machining (EDM) die-sinking is studied. The objective of this project is to determine the relationship between the machining parameters including pulse-on time, pulse-off time, peak current and voltage with the machining characterictics such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (Ra). Copper materials having diameter 15mm was chosen as the electrode tool. Design of experimenent using Taguchi technique was employed to design experimental matrix that was used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that current and pulse off time significantly affect MRR, EWR and Ra while pulse on time and voltage are less significant in their effect on machining responses. Results show that using Taguchi as a design matrix, the best setting of optimum value for machining parameters to find the required machining responses can be obtained.

The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminum Composite

2014 ◽  
Vol 699 ◽  
pp. 26-31 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Nor Atiqah Jaffar Sidek ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Aluminum Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The machining ability of Electrical Discharge Machining (EDM) die-sinking on material characteristics of LM6 (Al-Sil2) is studied. This is due to the machining process on sharp edge, pocket, deep slot and micro hole cannot be performed by milling and turning machine. The objective of this paper is to determine the relationship between the machining parameters such as pulse on time, pulse off time, peak current and voltage on material removal rate (MRR) that are electrode wear rate (EWR) and surface roughness (Ra). Graphite tool of diameter 15mm was chosen as an electrode. Taguchi method is used as analysis technique to develop experimental matrix that is used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that the current and pulse off time are significantly effected the MRR, EWR and Ra while pulse on time and voltage are less significant factors that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking

2014 ◽  
Vol 660 ◽  
pp. 43-47
Author(s):  
Amran Ali Mohd ◽  
Suraya Laily ◽  
Aisyah Fatin ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Aluminium Alloys ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

scholarly journals Evaluation of machining performance and multi criteria optimization of novel metal-Nimonic 80A using EDM

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Vikas K. Shukla ◽  
Rakesh Kumar ◽  
Bipin Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Minimum Energy ◽  
Process Parameter ◽  
Simultaneous Action ◽  
Peak Current ◽  
Nimonic 80A ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

AbstractThis study focused to machine novel Nimonic 80A through Electric Discharge Machine process. The process parameters are optimised to achieve high surface integrity along with high material removal rate (MRR) with minimum energy consumption. Central composite design along with analysis of variance technique has been applied to make correlation between the process parameter and responses. The developed model of surface roughness shows that the peak current and pulse-on time have significant effect whereas; a little effect of pulse-off time. The said result may be obtained due to simultaneous action of deposition and notching (removal) of material in order to form crater. In case of MRR, the pulse-on time and peak current are found as significant factors with increasing trend (i.e. when the input values are increased the MRR increases) whereas; a reverse trend is noticed with pulse-off time. The optimum values for maximum MRR (0.512444 gm/min) and minimum surface roughness (7.82203 µm) with 81% desirability are obtained for the process parameter as 13.49 A peak current, 150 µs pulse-on time and 4 µs pulse-off time.

Optimization of Machining Parameters on Tool Wear Rate of Ti-6Al-4V through EDM Using Copper Tungsten Electrode: A Statistical Approach

2010 ◽  
Vol 152-153 ◽  
pp. 1595-1602 ◽  
Author(s):  
M.M. Rahman ◽  
Md. Ashikur Rahman Khan ◽  
K. Kadirgama ◽  
M.M. Noor ◽  
Rosli A. Bakar
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Machining Process ◽  
Electrode Wear ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of peak ampere, pulse on time and pulse off time on tool wear rate (TWR) of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. A mathematical model for electrode wear rate is developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest TWR. Long pulse off time provides minimum TWR and the impact of pulse interval on TWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters.

Investigation the Electrode Wear Rate and Metal Removal Rate in EDM Process using Taguchi and ANOVA Method

2020 ◽  
Vol 38 (10A) ◽  
pp. 1504-1510
Author(s):  
Safaa K. Ghazi
Keyword(s):  
Wear Rate ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Metal Removal Rate ◽  
Electrode Wear Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The experimental work of this paper leads to electrical discharge machining (EDM). A system for machining in this process has been developed. Many parameters are studied such as current, pulse on-time, pulse off time of the machine. The main aim of this work is to calculate the metal removal rate (MRR) and electrode wear rate (EWR) using copper, electrodes when machining tool steel H13 specimens of a thickness (4mm). Different current rates are used ranging from (30, 42, and 54) Amp, pulse on-time ranging from (75, 100, and 125) and pulse off time ranging from (25, 50, and 75)   found that high current gives large electrode wear and metal removal rate and. The experiment design was by Taguchi Method. From an analysis of variance (ANOVA) the more active influence of input factors on the outputs is currently for metal removal rate (MRR) (58%) and electrode wear rate (EWR) (57).

The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminium Composite Using Tungsten Copper Electrode

2013 ◽  
Vol 465-466 ◽  
pp. 1214-1218 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Halida Ilyani Kamarudin Nor ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
New Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The machining ability of electrical discharge machining (EDM) die-sinking on aluminium LM6 (Al-Sil2) as a new material is investigated.The objective of this paper is to determine the relationship between the machining parameters which are pulse-on time, pulse-off time and peak current on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Tungsten copper tool of diameter 10mm was chosen as an electrode. Design of experiment using Taguchi method was used to develop experimental matrix and optimize the MRR, EWR and Ra. The analysis was done using the Minitab software. It is found that the current and pulse on time are significantly affected the MRR, EWR and Ra while pulse off time and voltage are less significant factor that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

Multi-Objective Optimization on Electric Discharge Machining Using by Grey Relational Analysis

2014 ◽  
Vol 592-594 ◽  
pp. 550-554
Author(s):  
L. Selvarajan ◽  
C. Sathiya Narayanan ◽  
R. Jeyapaul
Keyword(s):  
Ceramic Composite ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Grey Relational Grade ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing ◽  
Off Time

The present study ,Sparking parameters namely current (I), pulse on time (ton), pulse off time (toff), spark gap and dielectric flushing pressure (P) are optimized with the considerations of multi responses such as Material Removal Rate (MRR), Electrode wear Rate (EWR), of the MoSi2-SiC intermetallic/ceramic composite are investigated by use of the Taguchi L18 orthogonal array (OA) with grey relational grade analysis was reported.

Development of Mathematical Model for Predicting the Electric Erosion Behavior of TiO2 Filled Al-Zn-Mg-Cu (AA7075) Alloy Composite Using RSM-DFA Method

2020 ◽  
pp. 1-26
Author(s):  
S. V. Alagarsamy ◽  
M. Ravichandran ◽  
H. Saravanan
Keyword(s):  
Mathematical Model ◽  
Electrode Material ◽  
Electrode Materials ◽  
Pulse Current ◽  
Removal Rate ◽  
Electrode Wear ◽  
Alloy Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This work aims to develop a mathematical model and predict the machining performance characteristics of electric discharge machining (EDM) process using response surface methodology (RSM) coupled with desirability function approach (DFA). The effect of various factors, such as electrode material, pulse current, pulse ON time and pulse OFF time were selected as input process parameters with an objective to maximize the material removal rate (MRR), minimize the surface roughness (SR) and electrode wear ratio (EWR). The machining was conducted on Al-Zn-Mg-Cu (AA7075) alloy composite reinforced with 10[Formula: see text]wt.% TiO2 particulates produced by stir casting route. The experimental work was planned as per L27 orthogonal array using design of experiments through RSM. Experimental results show that, pulse current and pulse ON time are the most significant factors for MRR and SR while electrode materials and pulse current have notable effect on EWR. Finally, multi-response optimization was performed to predict the EDM parameters by using DFA. The optimum combination of parameters were identified as electrode material (Br), pulse current (15 amps), pulse ON time (900[Formula: see text][Formula: see text]s) and pulse OFF time (30[Formula: see text][Formula: see text]s).

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