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 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.

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. 

Optimization of machining parameters in chromium-additive mixed electrical discharge machining of the AA7075/5%B4C composite

2021 ◽  
pp. 095440892110317
Author(s):  
Vineet Dubey ◽  
Anuj K Sharma ◽  
Balbir Singh
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Condition ◽  
Dielectric Fluid ◽  
Optimum Process ◽  
Machining Parameters ◽  
Machined Surface ◽  
Pulse On Time ◽  
Pulse Off Time

The present study establishes the optimum process condition for additive mixed electrical discharge machining of Al7075–5%B4Cp metal matrix composite by performing experimental investigation. The suspension of chromium particles in a dielectric fluid is used as an additive. The input process parameters selected for experimentation are specifically pulse on-time, gap voltage, pulse off-time and peak current, for analysing their influence on wear of the tool along with surface roughness of the composite. Comparative study of the machined surface is done by analysing microstructures, cracks and recast layers formed at different settings of input parameters using a scanning electron microscope. Rise in amount of current and pulse on-time led to increased height of the recast layer generated on the surface of the machined workpiece. Furthermore, a confirmatory experiment was performed at the optimal setting. The result revealed an error of 5.5% and 7.5% between experimental and predicted value of tool wear rate and surface roughness.

The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminium Composite Using Tungsten Copper Electrode

2013 ◽  
Vol 465-466 ◽  
pp. 1214-1218 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Halida Ilyani Kamarudin Nor ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
New Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The machining ability of electrical discharge machining (EDM) die-sinking on aluminium LM6 (Al-Sil2) as a new material is investigated.The objective of this paper is to determine the relationship between the machining parameters which are pulse-on time, pulse-off time and peak current on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Tungsten copper tool of diameter 10mm was chosen as an electrode. Design of experiment using Taguchi method was used to develop experimental matrix and optimize the MRR, EWR and Ra. The analysis was done using the Minitab software. It is found that the current and pulse on time are significantly affected the MRR, EWR and Ra while pulse off time and voltage are less significant factor that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

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.

The Effect of EDM Die-Sinking Parameters on Non-Conductive Materials

2014 ◽  
Vol 903 ◽  
pp. 56-60 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Nor Assyura ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Plastic Material ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Metal Insert ◽  
Conductive Material ◽  
Conductive Materials ◽  
Current Voltage ◽  
Pulse On Time ◽  
Pulse Off Time

The machining ability of electrical discharge machining (EDM) die-sinking on acrylic as non-conductive material was studied. The objective of the study is to establish a new setup to machine a non-conductive material by using EDM die-sinking. Acrylic plastic material was selected as to represent the other groups of non-conductive materials. The experiment was conducted using a discharge sinking machine with copper as the tool electrode. Metal insert as conductive material was plug-in into acrylic workpiece. Polarity of the setup was set to positive at the copper electrode and negative at the plug-in metal insert. The variable input parameters such as electric discharge current, voltage, pulse on time and pulse off time had been observed to review machinibility of die-sinking EDM by taking the overcut and taper of sidewall of holes produced. It was found that the highest current supply during machining, the deepest hole occurred on the acrylic workpiece. Thus, the new method purposed on this study proved that non-conductive material can be machined using the EDM die-sinking.

scholarly journals Prediction of EDM Process Parameters for AISI 1020 Steel using RSM, GRA and ANN

2019 ◽  
Vol 8 (2S3) ◽  
pp. 51-63
Keyword(s):  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Discharge Voltage ◽  
Copper Electrode ◽  
Gray Relational Analysis ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

AISI 1020 Steel is hard while machining because of its nature of harness and brittleness. Electrical Discharge Machining (EDM) is a significant technique to machine such materials. Current research examines the pulse current effect (A), discharge voltage (B), pulse on time (C), pulse off time (D),Oil pressure (E)and spark gap(F) on Metal Removal Rate (MRR) and Surface Roughness on EDM of AISI 1020 Steel. Experiments have been carried out in a methodical type taking up nearly 54 successive trails utilizing an EDM machine and a copper electrode of 10mm diameter. Three factors, three levels, Box Bekhen through response surface methodology design was utilized to analyze the outcomes. Gray relational analysis techniques are adopted for finding parameter influencing range for MRR and SR. A multi regression mathematical model was brought up in launching the association between parameters of machining and artificial neural network techniques are used for predicting the optimized parameters.

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.

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

scholarly journals Multi-Objective Optimization of Process Parameters for Powder Mixed Electrical Discharge Machining of Inconel X-750 Alloy Using Taguchi-Topsis Approach

2021 ◽  
Vol 71 (1) ◽  
pp. 1-18
Author(s):  
Basha Shaik Khadar ◽  
Raju M. V. Jagannadha ◽  
Kolli Murahari
Keyword(s):  
Boron Carbide ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

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