Experimental Investigation of EDM Parameters on Al-LM6/SiC/B4C Hybrid Composites

2018 ◽  
Vol 877 ◽  
pp. 149-156 ◽  
Author(s):  
Manish Shukla ◽  
Pankaj Agarwal ◽  
Mohan Kumar Pradhan ◽  
S.K. Dhakad
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Material Removal ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Widespread Application ◽  
Pulse On Time

In this work, a Material removal rate (MRR), Tool wear rate (TWR), Radial and overcut (ROC), a study on the die-sinking Electrical discharge machining (EDM) of Al-LM6/SiC/B4C hybrid composites has been carried out. The selection of above-mentioned hybrid composite was made considering its widespread application in aerospace, automotive, defense, biomedical and marine industries, due to its light weight and higher mechanical properties. This experiment was made only for the finish stage and has been carried out on the influence of four design factors: composition, discharge current (Ip), Pulse-on-time (Ton), Radial overcut (ROC) and Duty factors (Tau), over the previously mentioned, responded variables. This has been done by means of the method of design of experiment (DOE) which allows us to carry out the above-mentioned analysis performing a relatively small number of experiments. The study indicates that when discharge current (Ip) increases, Material removal rate increased. In the case of Tool wear rate the most influencing factor is discharge current, then pulse on time. In radial over cut most influence factor is discharge current then pulse on time, duty factor and composition has least.

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.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

ELECTRICAL DISCHARGE MACHINING OF Al/7.5% Al2O3 MMCs USING ROTARY TOOL AND Al2O3 POWDER

2017 ◽  
Vol 24 (02) ◽  
pp. 1750018 ◽  
Author(s):  
SAEED DANESHMAND ◽  
BEHNAM MASOUDI ◽  
VAHID MONFARED
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Pulse On Time

Nowadays, composites are used in different parts of industries and it is one of the most important subjects. The most widely used reinforcements in metal matrix composites are Al2O3 and SiC fibers and particles which may be used in cutting-edge functional and structural applications of aerospace, defense, and automobile industries. Depending on the type of powder used, composite materials are difficult to machine by conventional cutting tools and methods. The most appropriate way for machining of these composites is electro discharge. For the reason of improving the surface quality, tool wear rate and material removal rate and reducing the cracks on the surface, Al2O3 powder was used. In this study, the effect of input parameters of EDM such as voltage, pulse current, pulse on-time and pulse off-time on output parameters like material removal rate, tool wear rate and surface roughness in both conditions of the rotary tool with powder mixed dielectric EDM and the stationary tool excluding powder mixed dielectric were investigated. The critical parameters were identified by variance analysis, while the optimum machining parameter settings were achieved via Taguchi method. Results show that using of powder mixed dielectric and rotary tool reduce the tool wear rate, surface roughness and the cracks on the surface significantly. It is found also that using of powder mixed dielectric and rotary tool improve the material removal rate due to improved flushing action and sparking efficiency. The analysis of variance showed that the pulse current and pulse on-time affected highly the MRR, TWR, surface roughness and surface cracks.

Realization of Surface Morphology and Process Parameter Optimization in MicroEDM Hole Drilling of Maraging Steel 300 Alloy

2015 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth ◽  
Ramya Alluru
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Maraging Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Micro Edm ◽  
Tool Wear Rate ◽  
Micro Holes ◽  
Pulse On Time

The Micro-Electrical Discharge Machining, popularly known as micro-EDM, is a nonconventional machining process mainly used for producing micro features like micro holes, micro gears, micro moulds etc. that are difficult to be obtained by conventional process. It can machine different types of conductive materials especially the ones which are difficult to cut and machine. Microholes have been drilled using micro-EDM process on various alloys like Ti-6Al-4V, Inconel 718 etc. using electrodes like Copper, Tungsten etc. The parts produced by micro-EDM are widely used in micro-electro-mechanical systems (MEMS), biomedical applications, automotive industry, and defence industry. Selection and use of correct process parameters is of paramount importance for achieving superior surface quality and higher machining rates while performing micro drilling. However, this process has been characterized by low tool wear rate, low machining rate and longer machining time as compared to other non-conventional processes. This paper aims at studying the influence of various process parameters while drilling micro holes on Maraging Steel 300 alloy using a brass electrode. Maraging Steel 300 alloy is widely used in aerospace, tooling and machinery applications. Brass was selected as the electrode material so as to know its influence in the microdrilling process as it is known for achieving high material removal rate along with high wear ratio. Machining parameters considered in this work were pulse on time, pulse off time, tool diameter and current. A total of 27 micro holes of 300 μm, 400 μm and 500 μm were drilled on Maraging Steel 300 alloy as per the orthogonal array design based Taguchi methodology. Experiments were carried out on Toolcraft V04056 micro-EDM machine. Dielectric used was distilled water. The output responses observed were material removal rate, tool wear rate and overcut. Analysis was carried out using signal to noise ratio analysis. Material removal rate, tool wear rate and overcut were found to be influenced mainly by pulse on time and current. In order to know and better understand the surface morphology of the micro-holes, SEM micro-graphs were obtained. Presence of spatters and re-deposited eroded material were observed in few of the drilled micro holes. The results were verified by performing confirmation experiment at the obtained optimum combination. The confirmation results were in close proximity to the predicted results.

CHARACTERIZATION OF ZrB2-SiC COMPOSITES WITH AN ANALYTICAL STUDY ON MATERIAL REMOVAL RATE AND TOOL WEAR RATE DURING ELECTRICAL DISCHARGE MACHINING

2016 ◽  
Vol 40 (3) ◽  
pp. 331-349 ◽  
Author(s):  
S. Sivasankar ◽  
R. Jeyapaul
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Relative Density ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Tool Materials

This research work concentrates on Electrical Discharge Machining (EDM) performance evaluation of ZrB2- SiC ceramic matrix composites with different tool materials at various machining parameters. Monolithic ZrB2 possesses lower relative density (98.72%) than composites. ZrB2 with 20 Vol.% of SiC possesses 99.74% of the relative density with improved hardness values. Bend strength and Young’s modulus increase with SiC addition until it reaches 20 Vol% and then decreasing. EDM performance on tool materials of tungsten, niobium, tantalum, graphite and titanium at various levels of pulse on time and pulse off time are analyzed. Graphite produces the best Material removal rate (MRR) for all the workpieces. Tool wear rate decreases with melting point and thermal conductivity of the tool material.

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.

Analysis of MRR and TWR on OHNS Die Steel with Different Electrodes Using Electrical Discharge Machining

2016 ◽  
Vol 22 ◽  
pp. 112-120 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Tool Wear Rate

Electrical Discharge Machining is a machining method primarily used for hard metals or those that are impossible to be machined with traditional techniques. The experimental investigation of material removal rate and tool wear rate during machining of oil hardened non-shrinking steel with brass and copper electrodes using EDM machine was carried out in this paper. This investigation presents the analysis and evaluation of heat affected zones and surface finish of the work piece using different tool electrodes and varying the machine parameters. The commercial grade kerosene oil has been used as dielectric fluid. The effect of various important EDM parameters such as discharge current (Ip) 2 to12A, pulse duration (Ton and Toff) and sparking voltage (V) of 80±5% have been used to yield the response in terms of Material Removal Rate (MRR) and Tool Wear Rate (TWR). Further a detailed analysis of the heat affected regions was also been carried out by using scanning electron microscopy.

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