Surface Quality Produced in EDM with Tungsten Carbide and Copper Compacted Electrodes

2015 ◽  
Vol 1115 ◽  
pp. 24-28 ◽  
Author(s):  
Ahsan Ali Khan ◽  
Mohammed Baba Ndaliman ◽  
Ummu Atiqah Khairiyah binti Mohamad ◽  
Nurul Farhana binti Sulong ◽  
Zakaria Mohd Zain
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Surface Hardness ◽  
Machining Performance ◽  
Peak Current ◽  
Work Surface ◽  
Machining Conditions ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) is one of the most commonly used technique to machine very hard materials. Materials like hardened tool steels, titanium and its alloys and difficult-to-machine materials can be easily processed with EDM. The machining performance to a great extent depends on the composition of the electrode. This paper presents the machining performance of powder metallurgy (PM) compacted electrodes made from titanium carbide (TiC) and copper (Cu) powders. The Cu-TiC electrodes made up of 70% of TiC and 30% of Cu powders. They were compacted at a pressure of 6,000 psi (41.34 MPa). Mild steel was used as the workpiece material. Machining was conducted with the peak current, pulse-on time and pulse-off time as the electrical input variables. The output variables of the investigation were work surface roughness and its hardness. It was found that work surface roughness increases with increase in current and pulse-on-time. However, it decreases with increase in pulse-off time. It was found that the highest value of surface roughness (14.782 μm) was found at highest peak current (6.5 A), highest pulse on-time (7.5 μs) and lowest pulse-off time (6.5 μs). The highest value of surface hardness (57.3 BHB) was found at the same machining conditions. The smoothest surface (14.782 μm) was found at the lowest peak current (3.5 A), lowest pulse on-time (6.0 μs) and highest pulse-off time (8.5 μs). The lowest value of surface hardness (42.9 BHB) was found at the same machining conditions.

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.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

scholarly journals Surface Roughness Prediction for Steel 304 In Edm Using Response Graph Modeling

2018 ◽  
Vol 14 (4) ◽  
pp. 115-124 ◽  
Author(s):  
Shukry H. Aghdeab ◽  
Nareen Hafidh Obaeed ◽  
Marwa Qasim Ibraheem
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Applied Current ◽  
Graph Modeling ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technique for metals removing which is relied upon the basic fact that negligible tool force is produced during the machining process. Also, electrical discharge machining is used in manufacturing very hard materials that are electrically conductive. Regarding the electrical discharge machining procedure, the most significant factor of the cutting parameter is the surface roughness (Ra). Conventional try and error method is time consuming as well as high cost. The purpose of the present research is to develop a mathematical model using response graph modeling (RGM). The impact of various parameters such as (current, pulsation on time and pulsation off time) are studied on the surface roughness in the present research. 27 samples were run by using CNC-EDM machine which used for cutting steel 304 with dielectric solution of gas oil by supplied DC current values (10, 20, and 30A). Voltage of (140V) uses to cut 1.7mm thickness of the steel and use the copper electrode. The result from this work is useful to be implemented in industry to reduce the time and cost of Ra prediction. It is observed from response table and response graph that the applied current and pulse on time have the most influence parameters of surface roughness while pulse off time has less influence parameter on it. The supreme and least surface roughness, which is achieved from all the 27 experiments is (4.02 and 2.12µm), respectively. The qualitative assessment reveals that the surface roughness increases as the applied current and pulse on time increases

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Effect of Electrical Discharge Machining on Surface Roughness of Cylindrical Shaped Parts

2020 ◽  
Vol 853 ◽  
pp. 13-17
Author(s):  
Le Hong Ky ◽  
Thi Hong Tran ◽  
Nguyen Van Cuong ◽  
Tran Thanh Hoang ◽  
Do Thi Tam ◽  
...  
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Optimum Input

This paper introduces an experimental study on the influence of electrical discharge machining (EDM) cylindrical shaped parts made of 90CrSi tool steel. In this work, some experiments were designed and analysed based on Taguchi method. Also, four input parameters including the pulse on time, the pulse off time, the current, and the server voltage were investigated. The influence of these parameters on the surface roughness were estimated by analysing variance. In addition, the optimum input parameters were found for getting the minimum surface roughness.

CFRP composite drilling through electrical discharge machining using aluminum as fixture plate

2021 ◽  
pp. 095440622110586
Author(s):  
Suvranshu Pattanayak ◽  
Ananda Kumar Sahoo ◽  
Susanta Kumar Sahoo
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Quality Attributes ◽  
Critical Parameters ◽  
Burr Formation ◽  
Hole Quality ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Recent developments in manufacturing require holes on composite materials, especially on the carbon fiber reinforced polymer (CFRP) with smooth hole periphery, low delamination, burr formation, taper, better circularity, and a high processing speed. Its non-conductive surface (epoxy layering) limits its machining through electrical discharge machining (EDM). To overcome this limitation, an aluminum fixture has been designed to guide the copper electrode of EDM for producing holes on a CFRP sheet of 1 mm thickness at low machining complexity, cost, time, delamination, burr in hole periphery and without affecting the material’s surface quality and performance. Even components with high geometrical complexity can also be drilled through this approach. Here, a multi-quality analysis called grey relational analysis is developed for examining the hole quality attributes, considering peak current, pulse on and off time, and flushing pressure as input parameters. This approach points out the optimum factor level setting and critical parameters (pulse-on time and peak current) that regulate the hole attributes (entrance and exit diameter, circularity, taper, material removal, and tool wear rate). An artificial neural network model has been designed and trained through experimental data sets. This model can also be adopted during the determination of hole quality attributes when the parameter settings are beyond a defined boundary, as the regression analysis value is very close to 1, and model performance is 4.99e-10. Peak current = 4 A, pulse-on time = 25 µs, pulse-off time=25 µs, and flushing pressure = 0.6 MPa were the optimum drilling parameters. In the initial hole, average burr length is 391.75 μm, and delamination of 539.3 μm is noticed. But burr formation is very negligible with delamination of 350.7 μm being observed with uniform circularity (0.979), low taper angle (−0.81354°), and TWR (0.000069 g/min) under optimum drilling conditions through this drilling approach.

Evaluation of Surface Roughness in Wire Electrical Discharge Turning Process

2021 ◽  
pp. 114-136
Author(s):  
Sibabrata Mondal ◽  
Dipankar Bose
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machine ◽  
Machining Performance ◽  
Discharge Machine ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Five Axis ◽  
Design Factors ◽  
Off Time

This investigation presents an experimental investigation in developing small cylindrical pins in electrolytic tough pitch copper (ETP Cu) material using wire electrical discharge turning (WEDT) to evaluate surface roughness of the cylindrical turning faces. The material ETP Cu is soft in nature and has growing range of application in the field of aerospace and electronics industries for advanced applications. In this process, a customized rotary spindle has been developed and added to five-axis CNC wire electrical discharge machine (WEDM) and straight turning of the cylindrical pin has been done up to a length of 15mm with 0.5mm diameter. Under this investigation, 31 experiments along with two confirmation tests have been carried out to study the influence of four design factors—pulse on time, pulse off time, spindle speed, and servo voltage—on the machining performance of surface roughness by means the technique of design of experiment (DOE).

Experimental Investigation of Process Parameters in Wire Electrical Discharge Machining by Response Surface Methodology on IS2062 Steel

2014 ◽  
Vol 550 ◽  
pp. 53-61
Author(s):  
R.Arun Bharathi ◽  
P.Ashoka Varthanan ◽  
K. Manoj Mathew
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Machining Parameters ◽  
Peak Current ◽  
Custom Design ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The objective of the present work is to predict the optimal set of process parameters such as peak current (IP), pulse on/off time (TON/TOFF) and spark gap voltage (SV) to achieve minimum Surface roughness (Ra), wire consumption rate (WCR) and maximum material removal rate (MRR). In this work, experiments were carried out by pulse arc discharges generated between ZnO coated brass wire and specimen (IS2062 steel) suspended in deionized water dielectric. The experiments were designed based on the above mentioned four factors, each having three levels. Custom design based Response Surface Methodology (RSM) is used in this research. 21 runs of experiments were constructed based on custom design procedure and results of the experimentation were analyzed analytically as well as graphically. Moreover the surface roughness after machining was measured by Taylor Hobson Surtronic device. Second order regression model has been developed for predicting Ra, WCR and MRR in terms of interactive and higher order machining parameters through RSM, utilizing relevant experimental data as obtained through experimentation. The research outcome identifies significant parametersand their effect on process performance on IS2062 steel. The results revealed that peak current, pulse on-time and their interactions have significant effects on Ra, whereas pulse off time and peak current have significant effects on MRR and it is also observed that peak current and interaction between peak current and pulse off time have significant effects on WCR. The adequacy of the above proposed models has been tested through the analysis of variance (ANOVA).

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.

Evaluating Influences of Input Parameters on Surface Roughness in Sinking EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 85-90
Author(s):  
Tran Thi Hong ◽  
Nguyen Anh Tuan ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Work Piece ◽  
Enabling Factors ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time ◽  
Optimum Input

The input parameters in the process of sinking Electrical Discharge Machining (EDM) are the essential enabling factors that need to be determined. In the present work, the influences of the EDM input parameters containing pulse on time (Ton), pulse off time (Toff), discharge current (IP), Server voltage (SV), work-piece diameter (dw) on the surface roughness (SR) in sinking EDM cylindrical shaped part of 9CrSi material were investigated. Taguchi technique and analysis of variance (ANOVA) have been used to identify the weight of EDM factors on SR. The results show that the impact level of Ton, Toff, IP, SP, and dw are 65.55%, 8.66%, 19.17%, 3.14%, and 0.76%, respectively. By analyzing the experimental results, optimum input parameters with the Ton of 6 ms, Toff of 30 ms, IP of 9A, SP of 3V, and dw of 10mm have been determined, that allow getting the best surface roughness.

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