Influence of Correlation between Electrical Discharge Machining Parameters with the Formation of Surface Defect’s in Products Machined by EDM

2011 ◽  
Vol 223 ◽  
pp. 950-959
Author(s):  
Ricardo Olinik ◽  
Paulo Andre de Camargo Beltrão
Keyword(s):  
Electric Discharge ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Hardness Profile ◽  
Machining Parameters ◽  
Premature Failure ◽  
Discharge Pulse ◽  
Electric Discharge Pulse

This paper shows a study of correlation between EDM´s parameters with the level of superficial defects development, which can lead to premature failure of die cast mold machined by EDM. The correlation of parameters was determined through experimental matrix that uses the DOE methodology (Design of Experiment). In order to evaluate the surfaces of some machined samples a stereo optical microscopy, SEM (the scanning electron microscope) and a micro hardness profile machine were used. The results show that in the worst machining condition, which is caused by association of long electric discharge pulse time-on and graphite machine-electrode, it is possible to minimize the amount of surface defects, without applying a subsequent machining process such as polishing, just using the reduced time-on´s electric discharge pulse, copper electrode and dielectric fluid with base of hydrocarbon.

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

An Investigation of the Influences of EDM Parameters and Tool Geometries on Radial Overcut for Monel 400 Material with Tungsten Copper Electrode

2015 ◽  
Vol 766-767 ◽  
pp. 908-913
Author(s):  
P. Padmini ◽  
S. Senthamilperarasu ◽  
B. Shanmuganathan ◽  
N.R.R. Anbusagar ◽  
P. Sengottuvel
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Copper Electrode ◽  
Machining Process ◽  
Experimental Result ◽  
Machining Parameters ◽  
Radial Overcut ◽  
Monel 400 ◽  
Pulse On Time

Electrical-discharge Machining (EDM) is a nonconventional machining process utilizing an electric spark discharge from the electrode (-) towards the work piece (+) through the dielectric fluid. The Dimensional accuracy in this is very important consideration for the accuracy of the finished product. The objective of this experimental study is to determine parameters that offer the best dimensional accuracy in electrical discharge machining (EDM). Discharge current (A), Pulse On Time (Ton), Pulse Off Time (Toff ) and Circle,Rectangle,Triangle and Square Tool Geometrical Shapes (Geo) are taken as machining parameters. The experimental investigations are carried out on Monel 400 material using Tungsten copper electrode. The response of ROC is considered for improving the machining efficiency. Optimal combination of parameters was obtained Taguchi Optimization technique. The confirmation experiments results shows that the significant improvement in Radial Overcut was obtained. ANOVA have been used to analyze the contribution of individual parameters on ROC. The experimental result demonstrates that the Taguchi method satisfies the practical requirements

Influence of Electrode Cooling on Recast Layers and Micro Crack in EDM of Titanium

2011 ◽  
Vol 264-265 ◽  
pp. 1180-1186 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Manufacturing Method ◽  
Conductive Materials ◽  
Hard Metals ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Electrical discharge machining (EDM) process is a manufacturing method for shaping hard metals and formation of deep and complex shaped hole by spark erosion in electrical conductive materials such as metals, metallic alloys, ceramics etc. EDM process is achieved by a series of recurring electrical discharges between the electrode and workpiece in the presence of dielectric fluid. EDM unique feature of using thermal energy to machine conductive materials irrespective of material hardness has been its major advantage in the manufacture of aerospace, surgical, mould, die, automotive and as well as sport components. The effectiveness of EDM process depends among other factors on the thermal properties of the electrode material. The objective of this study is to study the influence of electrode cooling on recast layers and micro crack in EDM of titanium. The machining parameters investigated in the present study are current intensity (I), pulse on-time (Ton), pulse off-time (Toff) and gap voltage (V), which are of great interest for EDM researchers. The copper electrode is used to EDM titanium workpiece at room temperature and at sub-zero temperature using liquid nitrogen. The influence of cooling of copper electrode on recast layers and micro crack on titanium were investigated using scanning electron microscope (SEM) and has been reported in this study.

scholarly journals An overview of major research areas in Wire cut EDM on different materials

2020 ◽  
Vol 12 (4) ◽  
pp. 33-48
Author(s):  
M. CHAITANYA REDDY ◽  
K. VENKATA RAO VENKATA RAO
Keyword(s):  
Electrical Discharge Machining ◽  
Surface Characteristics ◽  
Machining Process ◽  
Material Surface ◽  
Dielectric Fluid ◽  
Major Research ◽  
Electrically Conductive ◽  
Premature Failure ◽  
Research Areas ◽  
Ultrasonic Assisted

WEDM (Wire electrical discharge machining) is a precision machining method for cutting electrically conductive materials. It is an unconventional machining process that produces precision parts that match the dimensional tolerances of our designs within the range of ±0.0001mm. As the residual stress results in premature failure of parts, the WEDM is preferred for hard to machine materials such as Inconel, Nickel, and other Super alloys. In the present paper, earlier and recent work was reviewed, segregated and evaluated on the effect of wire material, diameter, dielectric fluid, wire wear, pulse on and off times and machining characteristics such as kerf size, machining efficiency, material surface characteristics, etc. This paper also focused on hybrid and ultrasonic-assisted WEDM used for machining of different materials. This paper discussed the major research studies in WEDM.

An extensive review on sustainable developments of dry and near-dry electrical discharge machining processes

2021 ◽  
pp. 1-37
Author(s):  
Sampath Boopathi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Working Fluid ◽  
Dielectric Fluid ◽  
Extensive Literature ◽  
Machining Processes ◽  
Research Activities ◽  
Dry Edm

Abstract Electrical discharge machining (EDM) is very essential unconventional electro-thermal machining process to machine the contour profile of hard materials in modern production industries. The liquid dielectric fluid has been replaced by the gas and minimum quantity of liquid mixed with gas (gas-mist) to encourage the green machining processes. The various gases and gas-mist have been used as the working fluid in dry and near-dry EDM respectively. The research-contextual, various dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques applied in various dry and near-dry EDM have been illustrated through an extensive literature survey. Future research opportunities in both dry and near-dry EDM have been summarized to promote eco-friendly EDM research activities.

scholarly journals Parametric optimization of wire cut electrical discharge machining

2014 ◽  
Vol 3 (2) ◽  
pp. 212
Author(s):  
M. Durairaj ◽  
A.K.S. Ansari ◽  
M. H. Gauthamkumar
Keyword(s):  
Surface Roughness ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Fluid Pressure ◽  
Performance Criteria ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. 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. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

Multi Response Optimization of Electrical Discharge Machining Process Parameters Using Sintered Copper Electrode

2012 ◽  
Vol 622-623 ◽  
pp. 19-24
Author(s):  
P. Balasubramanian ◽  
Thiyagarajan Senthilvelan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Sintered Copper ◽  
Response Optimization ◽  
Electric Pressure ◽  
Pulse On Time

In this study, input parameters of Electrical Discharge machining (EDM) process have been optimised for two different materials EN-8 and Die steel-D3 were machined by using sintered copper electrode. Analysis of variance (ANOVA) was applied to study the influences of process parameters viz: - peak current, pulse on time, di-electric pressure and diameter of electrode on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) for both materials. Response surface methodology (RSM) has been applied to optimise the multi responses in order to get maximum MRR, minimum TWR and minimum SR. Furthermore, mathematical model has been formulated to estimate the corresponding output responses for both work pieces. It has been observed that compared to EN 8 material, the MRR value is low and TWR is high for D3 material. However the SR value is marginally lower than obtained in EN8.R2 value is above 0.90 for both work pieces.

Electrode Material Effect on Electrical Discharge Machining PcBN Cutting Tool Processing

2011 ◽  
Vol 399-401 ◽  
pp. 1667-1671 ◽  
Author(s):  
Yun Hai Jia
Keyword(s):  
Surface Quality ◽  
Electric Discharge ◽  
Electrode Material ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Electric Discharge Machining ◽  
Tool Surface

The electrode material is playing the very important role in the electrical discharge machining. Two kinds of electrode materials common used in EDM are compared and analyses similarities and differences in structure and physical characteristics. Combined with PcBN tool machining tests, from the electric discharge machining efficiency, electrode wear, tool surface quality, tool surface degenerating layer, machining results are in analysis and comparison, and then different electrode materials machining technics in electrical discharge machining process are summarized. Through the cutting tool electric discharge machining experiments, we can know that the graphite electrode easy to take shape, suits in the complex edge's cutting tool electric discharge machining, under the same electric discharge machining parameter condition, its processing efficiency must be higher than the copper electrode, but the electrode loses, the cutting tool surface quality and affect layer thickness are to be worse than the copper electrode.

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