Determination of Material Removal Rate and Radial Overcut in Electro Discharge Machining of AISI 304 Using Dimensional Analysis

2016 ◽  
Vol 852 ◽  
pp. 160-165 ◽  
Author(s):  
Munmun Bhaumik ◽  
Kalipada Maity ◽  
Kasinath Das Mohapatra
Keyword(s):  
Dimensional Analysis ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Aisi 304 ◽  
Radial Overcut ◽  
Electro Discharge Machining ◽  
Work Material

Electro discharge machining (EDM) is a most commonly used machining process among all the non-conventional machining process which removes materials via electrical and thermal energy. The primary goal of EDM is to get more material removal rate (MRR) with lower radial overcut (ROC). Normally, the responses are predicted using empirical models which are limited to only machining parameters and they do not consider the effects of work material properties on the process performance. Therefore in this study, a model has been developed including machining parameter as well as thermo-physical property of work material. In this investigation, a semi-empirical model has been established for the material removal rate (MRR) and radial overcut (ROC) by adopting the dimensional analysis technique. Dimensional analysis is a technique of dimensions and a mathematical technique that deals with the physical quantities concerned with the experiments to formulate a model for the response in terms of response control parameters as well as some physical properties of the materials. Buckingham’s л theorem is a main theorem in dimensional analysis and it is a signification of Rayleigh’s method of dimensional analysis. The theory is applied to gather each and every variable presenting the problem in a number of the dimensionless products. For this study, the thermo-physical properties viz. density, thermal conductivity and coefficient of thermal expansion and machining parameters like peak current, pulse on time, gap voltage and duty cycle are considered as input factor. AISI 304 stainless steel used as work material and Tungsten carbide is used as tool material for this investigation.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

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.

Multi Response Optimization by Using the Hybrid Technique in Electro Discharge Machining of AISI 304

2016 ◽  
Vol 26 ◽  
pp. 68-75 ◽  
Author(s):  
Munmun Bhaumik ◽  
Kali Pada Maity
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Aisi 304 ◽  
Relational Analysis ◽  
Electro Discharge Machining ◽  
Grey Relational

Electro discharge machining (EDM) is most popular non-conventional electro-thermal machining process where electrical energy is used to generate a spark and thermal energy used to remove material from the workpiece. The primary goal of EDM is getting more material removal rate (MRR) with lower tool wear rate (TWR). For this investigation, machining parameters like peak current, pulse on time, gap voltage and duty cycle are considered as process parameter, and material removal rate (MRR) and tool wear rate (TWR) are considered as response. AISI 304 stainless steel and tungsten carbide are used as work material and tool material respectively. Taguchi L27 orthogonal array has been applied for designing the experiment. A hybrid optimization technique like desirability in combination with grey relational analysis (GRA) has been performed to get the optimum level of the control parameter for getting higher MRR and lower TWR. Analysis of variance (ANOVA) is performed for the statistical analysis. These results show that peak current is the most significant parameter for MRR and TWR. The optimal parameter setting for maximum MRR and minimum TWR has obtained by desirability coupled with Grey relational analysis.

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

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.

Study on Compound Machining of Polyurethane Polishing Pad and Cluster Abrasive Brush Based on MR Effect

2011 ◽  
Vol 487 ◽  
pp. 238-242 ◽  
Author(s):  
Min Li ◽  
Qiu Sheng Yan ◽  
Jia Bin Lu ◽  
Jing Fu Chai
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Polishing Process ◽  
Workpiece Material ◽  
Crystal Silicon ◽  
Polishing Pad ◽  
Mr Effect

Method of compound machining is used to process single crystal silicon and SrTiO3 ceramic substrates, and the factors on effects of compound machining are studied such as magnetic field intensity, processing time, rotating speed of lapping plate and lapping pressure. The results show that the roughness of work pieces processed by compound machining are smaller than that by lapping based on cluster MR effect and polyurethane pad polishing process, while the material removal rate is higher than polyurethane pad polishing process, therefore, compound machining shows its synergistic effect between lapping based on cluster MR effect and polyurethane pad polishing process. The type and properties of workpiece material, and machining parameters both have a significant impact on the roughness and material removal rate of compound machining process of polyurethane polishing pad and cluster abrasive brush based on MR effect.

scholarly journals Optimization of Turning Parameter of Composite Materials Using Response Surface Method in Minitab

2021 ◽  
Author(s):  
S. S Kulkarni ◽  
Sarika Sharma
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Rsm Optimization

This paper represents the optimization method utilized in machining process for figuring out the most advantageous manner design. Typically, the technique layout parameters in machining procedures are noticeably few turning parameters inclusive of reducing velocity, feed and depth. The optimization of speed, feed depth of cut is very tough because of several other elements associated with processing situations and form complexities like surface Roughness, material removal rate (MRR) that are based Parameters. On this task a new fabric glass fibre composite is introduced through which could lessen costing of manufacturing and time and additionally it will boom the technique of productiveness. Composite substances have strength, stiffness, light weight, which gives the large scope to engineering and technology. The proposed research work targets to analyze turning parameters of composite material. The machining parameters are very important in manufacturing industries. The present research work is optimized surface roughness of composite material specifically in turning procedure with the aid of changing parameter including intensity of reduce, slicing velocity and feed price and additionally expect the mechanical houses of composite material. The RSM optimization is important because it evaluates the effects of multiple factors and their interactions on one or more responsive variables. It is observed that the material removal rate increases and surface roughness decreases as per the increase of Spindle speed and feed rate.

An Orthogonal Experimental Study of WEDM-HS of Particle-Reinforced 6061 Al Matrix Composites with 20-Vol% Al2O3

2014 ◽  
Vol 563 ◽  
pp. 21-24 ◽  
Author(s):  
Jiang Wen Liu ◽  
Yong Zhong Wu
Keyword(s):  
Pulse Duration ◽  
Material Removal Rate ◽  
Duty Cycle ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Al Matrix Composites ◽  
Al Matrix

An investigation has been made into the machining feasibility when wire electro-discharge machining with an extremely high travelling speed of wire electrode (WEDM-HS) has been employed to process particle-reinforced 6061 Al matrix composites with 20-vol% Al2O3 (20ALO). And in this study, for the water based emulsion is used as working liquid, there exists an electrochemical effect. And thus, the EDM spark can operate under a relatively large spark gap size condition, and this would be helpful for the removal of the loosen particles and the machined debris. In this study, the material removal rate (MRR) has been examined. Since there are many factors that can influence the MRR during the wire electro-discharge machining process, in order to determine which factor has the most significant effect on the MRR and to obtain the optimal machining parameters, the relative importance of the various machining parameters on material removal rate was analysed by employing an orthogonal design. The results of the orthogonal analysis show that to obtain a high MRR for WEDM-HS machining of 20ALO materials, the duty cycle has the most significant effect on the MRR among current, pulse duration and duty cycle. And the impact of significance for the different factors follows the sequence of duty cycle > current > pulse duration. And under the experiment condition of this study, a duty cycle of 1:4, a current of 5A and a pulse duration of 32μs is the best arrangement for the MRR.

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