Electric Discharge Machining of Cryo-Treated NiTi Alloys

2015 ◽  
Vol 787 ◽  
pp. 366-370 ◽  
Author(s):  
Vaibhav Gaikwad ◽  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Workpiece Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Conventional Machining

NiTi alloys possess superior material properties such as high specific strength, high corrosion resistance, high wear resistance and high anti-fatigue property. Due to these properties it is difficult to machine these alloys using conventional machining process. Nowadays non-conventional machining processes are widely used for machining such adavanced materials. Electrical Discharge machining (EDM) is one such non-conventional process, which can machine electrically conductive materials of any hardness values. Present study aims at drilling mesoscale 3 mm square holes on NiTi alloy by varying the electrical parameters namely, gap current, pulse on time and pulse off time. Additional, the present work includes finding out the effect of cryogenic treatment of NiTi work material on electrical discharge machining performance measures namely material removal rate (MRR) and tool wear rate (TWR). Based on experiments conducted, it can be concluded that with increase in current both material removal rate and tool wear rate increases. It is also noted that cryo-treatment of workpiece material improves MRR with respect to gap current. Similarly there is an increase in MRR with respect to pulse on time and pulse off time for cryo-treated workpiece material. There is a slight improvement of TWR with respect to gap current, pulse on time and pulse off time for cryo-treated workpiece material.

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.

Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
G. Ramanan ◽  
R. Elangovan
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

Fabrication and experimental investigation of magnetic field assisted powder mixed electrical discharge machining on machining of aluminum 6061 alloy

2019 ◽  
Vol 233 (12) ◽  
pp. 2283-2291 ◽  
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Pulse On Time

Magnetic field assisted powder mixed electrical discharge machining is a hybrid machining process with suitable modification in electrical discharge machining combining the use of magnetic field and fine powder in the dielectric fluid. Aluminum 6061 alloy has found highly significance for the advanced industries like automotive, aerospace, electrical, marine, food processing and chemical due to good corrosion resistance, high strength-to-weight ratio, ease of weldability. In this present work, magnetic field assisted powder mixed electrical discharge machining setup was fabricated and experiments were performed using one factor at a time approach for aluminum 6061 alloy. The individual effect of machining parameters namely, peak current, pulse on time, pulse off time, powder concentration and magnetic field on material removal rate and tool wear rate was investigated. The effect of peak current was found to be dominant on material removal rate and tool wear rate followed by pulse on time, powder concentration and magnetic field. Increase in material removal rate and tool wear rate was observed with increase in peak current, pulse on time and a decrease in pulse off time, whereas, for material removal rate increases and tool wear rate decreases up to the certain value and follow the reverse trend with an increase in powder concentration. Material removal rate was increased and tool wear rate was decreased with increase in magnetic field.

Analysis of the electrical discharge machining (EDM) performance on Ramor 550 armor steel

2020 ◽  
Vol 62 (5) ◽  
pp. 481-491
Author(s):  
Engin Nas
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Processing Parameters ◽  
Depth Of Cut ◽  
Armor Steel ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Abstract This study investigated the electrical discharge machining (EDM) performance of Ramor 500 Armor steel, a material used in the defense industry for armor production. In addition, the surface quality and amount of material wear of the treated surfaces were determined using different electrical discharge processing parameters for a copper electrode including pulse on-time (99, 150, 225, 300, 351 μs), pulse off-time (10, 15, 23, 30, 35 μs), and discharge current (3, 4, 6, 8, 9 A), at a constant pressure of 1 mm depth of cut. As a result of the experiments, the values related to the material removal rate (MRR) and the surface roughness (Ra) were obtained and the findings analyzed via response surface methodology (RSM). The increase in amperage and pulse on time resulted in an increase in Ra and MRR values. The minimum and maximum Ra and MRR values emerged at currents of 3 and 9 A, respectively. In the experiments performed applying currents of between 3 and 9 A, the white layer widths were measured as 0.0474 mm and 0.0915 mm, respectively. The statistical test results showed that the most effective processing parameters for the MRR were the discharge current amperage (49.01 %) and the pulse off-time (16.51 %), whereas the most effective parameter for the Ra value was the discharge current amperage (79.07 %).

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

2021 ◽  
pp. 095440892110607
Author(s):  
Sadananda Chakraborty ◽  
Souren Mitra ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Powder Concentration ◽  
Pulse Off Time ◽  
Off Time

Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

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 Parameter Optimization of Wire EDM for H-13 Tool Steel

2018 ◽  
Vol 8 (01) ◽  
Author(s):  
Satish Giduturi ◽  
Ashok Kumar
Keyword(s):  
Tool Steel ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Wire Feed

Wire Electrical Discharge Machining (WEDM) is a widely accepted non-traditional material removal process used to manufacture components with intricate shapes and profiles. It is considered as a unique adaptation of the conventional EDM process, which uses an electrode to initialize the sparking process. H13 Hot Work Tool Steel has high hot tensile strength, hot wear-resistance and toughness. Good thermal conductivity and insensitiveness to hot cracking, making it suitable not only for hot die applications but also plastic moulds. In this study, it is found that most predominant factors for the maximum material removal rate which is 22.21 mm3/min are current which was found to be 200A and Pulse ON Time 125 µs, however rest four factors (voltage 20V, pulse off time 40µs, wire tension 8N and wire feed 7mm/min) has less impact as compare to the predominant factors. The most predominant factors for Minimum surface roughness which is 0.89µm are wire tension 10N, pulse on time 115µs and servo voltage 60V. However, rest three factors pulse off time 60 µs, peak current 140 A and wire feed 7mm/min has less impact as compare to the predominant factors.

scholarly journals Optimization and modeling of Electrical Discharge parameters on Machining of Stavax Steel

2020 ◽  
Vol 6 (11) ◽  
pp. 53-62
Author(s):  
P Srinivasa Rao and Prof. Eshwara Prasad Koorapati
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Linear Regression Analysis ◽  
Performance Characteristics ◽  
Dielectric Fluid ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This work focuses on the use of the Taguchi method in order to find out the optimized parameters of the process like discharge current, pulse on time and pulse off time on the machining features such as material removal rate(MRR), surface roughness(SR) & tool wear rate(TWR) on Stavax Steel by means of Electrical Discharge Machining(EDM). It is also intended to study the individual influence of parameters on the performance characteristics. The dielectric fluid circulating system is modified to conduct the experiments. The analysis of variance (ANOVA) is made to recognise the importance of parameters on the response. By using non-linear regression analysis the empirical models are developed in order to predict these performance characteristics and the confirmation test was conducted at the optimal parameters settings to check the optimum expected values of performance features. Detailed analysis by using ANOVA is done and came out with the findings as a pulse on time is the most significant process parameter, next is the discharge current and the insignificant parameter is the pulse off time. Machining surface morphology was studied and observed that crater size is large and deeper due to a large amount of metal is melted and vaporized at the optimum condition of MRR.

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