Parametric Optimization of PMEDM Process with Chromium Powder Suspended Dielectric for Minimum Surface Roughness and Maximum MRR

2011 ◽  
Vol 383-390 ◽  
pp. 3202-3206 ◽  
Author(s):  
Rajiv Kumar Garg ◽  
Kuldeep Ojha
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Material Removal ◽  
Parametric Optimization ◽  
Nickel Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Chromium Powder ◽  
Average Current

In this article, parametric optimization for material removal rate (MRR) and surface roughness (SR) study on the powder mixed electrical discharge machining (PMEDM) of EN-8 steel has been carried out. Response surface methodology (RSM) has been used to plan and analyze the experiments. Average current, duty cycle, diameter of electrode and concentration of micro-nickel powder added into dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance in terms of MRR and SR. Experiments have been performed on newly designed experimental setup developed in laboratory. Most important parameters affecting selected performance measures have been identified and effects of their variations have been observed.

Parametric Optimization of PMEDM Process with Chromium Powder Suspended Dielectric for Triangular Electrodes

2013 ◽  
Vol 816-817 ◽  
pp. 23-27
Author(s):  
Rajiv Kumar Garg ◽  
Kuldeep Ojha
Keyword(s):  
Performance Measures ◽  
Electrical Discharge ◽  
Material Removal ◽  
Parametric Optimization ◽  
Nickel Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Chromium Powder ◽  
Average Current

In this article, parametric optimization for material removal rate (MRR) and surface roughness (SR) study on the powder mixed electrical discharge machining (PMEDM) of EN-8 steel has been carried out. Response surface methodology (RSM) has been used to plan and analyze the experiments. Average current, duty cycle, diameter of electrode and concentration of micro-nickel powder added into dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance in terms of MRR and SR. Experiments have been performed on newly designed experimental setup developed in laboratory. Most important parameters affecting selected performance measures have been identified and effects of their variations have been observed.

Surfactant and graphite powder–assisted electrical discharge machining of titanium alloy

2016 ◽  
Vol 231 (4) ◽  
pp. 641-657 ◽  
Author(s):  
Murahari Kolli ◽  
Adepu Kumar
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Recast Layer ◽  
Dielectric Fluid ◽  
Recast Layer Thickness

Surfactant and graphite powder–assisted electrical discharge machining was proposed and experiments were performed on titanium alloy in this investigation. Analysis was carried out to observe changes in dielectric fluid behaviour, material removal rate, surface roughness, recast layer thickness, surface topography and energy-dispersive X-ray spectroscopy. It was found out that the addition of surfactant to dielectric fluid (electrical discharge machining oil + graphite powder) improved the material removal rate and surface roughness. It was noticed to have reduced the recast layer thickness and agglomeration of graphite and sediment particles. Biface material migrations between the electrode and the workpiece surface were identified, and migration behaviour was powerfully inhibited by the mixing of surfactant. Surfactant added into dielectric fluid played an important role in the discharge gap, which increased the conductivity, and suspended debris particles in dielectric fluid reduced the abnormal discharge conditions of the machine and improved the overall machining efficiency.

scholarly journals Investigation into effects/Investigating the effects of titanium powder concentrations mixed in dielectric fluid on material machining removal and surface roughness of SKD61 steel after electrical discharge machining by reverse electrode polarity

2015 ◽  
Vol 18 (2) ◽  
pp. 43-51
Author(s):  
Long Tien Banh ◽  
Cuong Ngo ◽  
Phan Huu Nguyen
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Material Removal ◽  
Titanium Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Electrode Polarity ◽  
Edm Process

Electrical discharge machining (EDM) has found widespread applications in tool , mold and aerospace industries. Therefore, enhancement of the quality of the EDM process has become a major research concern. In this paper, the effect of various titanium powder concentrations on the Material Removal Rate (MRR), tool wear rate (TWR), surface roughness (Ra) in powder mixed electrical discharge machining (PMEDM) have been studied. The workpiece is SKD61steel and electrode made from copper with reverse polarity were used in experimental study. The results showed that titanium powder mixed into the dielectric fluid of EDM can enhance MRR without increasing TWR and Ra.

scholarly journals The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

2020 ◽  
Vol 10 (1) ◽  
pp. 401-407
Author(s):  
Yanuar Rohmat Aji Pradana ◽  
Aldi Ferara ◽  
Aminnudin Aminnudin ◽  
Wahono Wahono ◽  
Jason Shian-Ching Jang
Keyword(s):  
Surface Roughness ◽  
Metallic Glasses ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Recast Layer ◽  
Surface Evaporation ◽  
Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

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.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

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