Optimization of Machining Parameters on Surface Roughness in EDM of Ti-6Al-4V Using Response Surface Method

2011 ◽  
Vol 213 ◽  
pp. 402-408 ◽  
Author(s):  
M.M. Rahman ◽  
Md. Ashikur Rahman Khan ◽  
M.M. Noor ◽  
K. Kadirgama ◽  
Rosli A. Bakar
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Surface Finish ◽  
Machining Parameters ◽  
Surface Method ◽  
Superior Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents the influence of EDM parameters in terms of peak ampere, pulse on time and pulse off time on surface roughness of titanium alloy (Ti-6Al-4V). A mathematical model for surface finish is developed using response surface method (RSM) and optimum machining setting in favor of surface finish are evaluated. Design of experiments (DOE) techniques is implemented. Analysis of variance (ANOVA) has been performed to verify the fit and adequacy of the developed mathematical models. The acquired results yield that the increasing pulse on time causes fine surface till a certain value and then deteriorates the surface finish. It is investigated that about 200 µs pulse off time produce superior surface finish. These results lead to desirable surface roughness and economical industrial machining by optimizing the input parameters.

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 Findings of performance evaluation of EDM for different materials of electrodes and work pieces- a review

2018 ◽  
Vol 7 (4.5) ◽  
pp. 542
Author(s):  
Harshalkumar R. Mundane ◽  
Dr. A. V. Kale ◽  
Dr. J. P. Giri
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Performance Measure ◽  
Machining Process ◽  
Machining Parameters ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

EDM (Spark erosion) is non-conventional machining process which uses as removing unwanted material by electrical spark erosion. EDM Machining parameters affecting to the performance and the industries goal is to produce high quality of product with less time consuming and cost. To achieve these goals, optimizing the machining parameters such as pulse on time, pulse off time, cutting speed, depth of cut, duty cycle, arc gap, voltage etc. The performance measure of EDM is calculated on the basis of Material Remove Rate(MRR), Tool Wear Rate(TWR), and Surface Roughness(SR).The main objective of present work is to investigate of the influence of input EDM (Electro Discharge Machining) parameters on machining characteristics like surface roughness and the effects of various EDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, on different process response parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), tool wear ratio(TWR)and surface integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness (SR) and work piece material have been discussed.   

A Comparison of the Effects of Wire Electrical Discharge Machining Parameters on the Processing of Traditionally Manufactured and Additively Manufactured 316L Stainless Steel Specimens

2018 ◽  
Author(s):  
Gregory Bicknell ◽  
Guha Manogharan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
316L Stainless Steel ◽  
Machining Parameters ◽  
Wire Edm ◽  
Machining Time ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electric discharge machining (EDM) is a non-traditional machining method that has the ability to machine hard, conductive materials, with no force and high precision. This technology is used in industries, like the aerospace industry, to create precision parts used in high stress applications. Wire EDM is also commonly used in additive manufacturing (AM) applications to remove printed parts from the base-plates onto which they are printed. Numerous studies show the effects of EDM parameters, like pulse-on time, pulse-off time, and cutting voltage, on the processing of traditionally fabricated metal parts. However, very few studies identify how the parameters of wire EDM affect the processing of AM parts. This paper studies the effect of wire EDM pulse-on time, pulse-off time, and cutting voltage on the machining time, surface roughness, and hardness of additively manufactured 316L stainless steel cylinders. The effects of these wire EDM parameters are then tested on the machining time, surface roughness, and hardness of wrought 316L stainless steel cylinders. It was found that machining time of AM samples was statistically significantly lower than wrought samples and also had better surface finish and lower surface hardness.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

scholarly journals Taguchi Optimization In Machining Inconel 600 With WEDM Process Using Cryogenically Treated Brass Wire

2021 ◽  
Vol 309 ◽  
pp. 01110
Author(s):  
K. Satyanarayana ◽  
B Ramya Krishna ◽  
M. Bhargavi ◽  
R. Eswari Vasuki ◽  
K. Raj Kiran
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Inconel 600 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time ◽  
Brass Wire

Wire electric discharge machining (WEDM) is one amongst the unconventional machining processes which might cut all kinds of shapes with an accuracy of +/−0.001mm. It will cut the materials that conduct electricity and can even cut the exotic metals like tungsten carbide, Hastelloy, Inconel etc. In the present work, machining on Inconel 600 by wire EDM with cryogenically treated brass wire is performed. Brass wire of 0.25mm diameter has been cryogenically treated at −90°C, −100°C and −110°C temperatures separately. An Experimental layout is designed as per Taguchi’s L-9 orthogonal array and experiments were conducted by varying machining parameters viz. Voltage, Pulse ON time and Pulse OFF time. The machining parameters are optimized using Taguchi’s methodology for minimum surface roughness and maximum metal removal rate (MRR). A Mathematical regression model for surface roughness and MRR is generated with the help of regression analysis. Through the Analysis of Variance (ANOVA) It was found that for MRR, pulse on time is the foremost contributing factor with 32.69% and for surface roughness, pulse off time is the foremost contributing factor with 23.59%.

Analysis of Effects of Machining Parameters on Surface Roughness in Electrical Discharge Machining Tablet Shape Punches Using Taguchi Method

2020 ◽  
Vol 977 ◽  
pp. 12-17
Author(s):  
Thi Hong Tran ◽  
Tien Dung Hoang ◽  
Hong Ky Le ◽  
Thi Tam Do ◽  
Thanh Hien Bui ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Machining Parameters ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents a study on analysis of influences of the surface roughness in Electrical Discharge Machining 90CrSi tablet shape punches with the use of copper electrode. In this paper, 9 experimental runs were designed and conducted by using Taguchi method. In addition, 4 process parameters including the gap voltage, the pulse current, the pulse on time and the pulse off time were investigated. The influences of these input parameters on the surface roughness were evaluated by analysing variance. Also, from the experimental results, optimum values of the input parameters for getting the minimum surface roughness were proposed.

Modeling and Optimization of EDM of Al 7075/10wt% Al2O3 Metal Matrix Composites by Response Surface Method

2012 ◽  
Vol 488-489 ◽  
pp. 856-860 ◽  
Author(s):  
S. Gopalakannan ◽  
Thiyagarajan Senthilvelan ◽  
K. Kalaichelvan
Keyword(s):  
Response Surface ◽  
Response Surface Method ◽  
Process Parameters ◽  
Metal Matrix ◽  
Removal Rate ◽  
Electrode Wear ◽  
Influence Of Process Parameters ◽  
Surface Method ◽  
Pulse On Time ◽  
Pulse Off Time

The newly engineered metal matrix composite (MMC) of aluminium 7075 reinforced with 10 wt% of Al2O3 particles were prepared by stir casting method. Electrical discharge machining (EDM) was employed to machine MMC with copper electrode. The experiment plan adopts face centered central composite design of response surface methodology. Analysis of variance was applied to investigate the influence of process parameters and their interactions viz., pulse current, gap voltage, pulse on time and pulse off time on material removal rate (MRR), electrode wear ratio (EWR) and surface roughness (SR). The objective was to identify the significant process parameters that affect the output characteristics. Further a mathematical model has been formulated by applying response surface method in order to estimate the machining characteristics such as MRR, EWR and SR.

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.

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