Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V

2011 ◽  
Vol 418-420 ◽  
pp. 1478-1481 ◽  
Author(s):  
Manoj Modi ◽  
Gopal Agarwal
Keyword(s):  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Hybrid Machining ◽  
Hard Materials ◽  
Hybrid Machining Process ◽  
Pulse On Time

Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.

Influence of Dielectric Jet Flushing during Electro Discharge Diamond Surface Grinding Process

2013 ◽  
Vol 652-654 ◽  
pp. 2187-2190
Author(s):  
Gopal Agarwal ◽  
Manoj Modi
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Hybrid Machining Process

The influence of dielectric jet flushing during Electro Discharge Diamond Surface Grinding (EDDSG) on Ti-6A-4V has been reported in this paper. The metal bonded diamond grinding wheel is used as electrode in Electro Discharge Diamond Surface Grinding process. In this process mechanical grinding is coupled with electrical spark of electrical discharge machine to take up the advantages associated with hybrid machining process. The important input parameters in this investigation were “duty factor”, “wheel speed (rpm)”, “magnitude of current (ampere)” and its “duration (Ton, micro-second)”. The effects of these parameters on outcomes i.e. material removal rate (MRR) and surface roughness (Ra) are measured. The noticeable enhancements in material removal rate and surface finish have been seen during EDDSG of Ti-6Al-4V with effective jet flushing. The performance of EDDSG with jet flushing and without jet flushing has been compared.

Experimental investigations of slotted electrical discharge abrasive grinding of Al/SiC/Gr composite

2015 ◽  
Vol 231 (6) ◽  
pp. 945-955 ◽  
Author(s):  
Ravindra Nath Yadav ◽  
Vinod Yadava
Keyword(s):  
Metal Matrix ◽  
Electrical Discharge ◽  
Removal Rate ◽  
Wheel Speed ◽  
Machining Process ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Aluminum Silicon Carbide ◽  
Pulse On Time ◽  
Pulse Off Time

Machining of metal matrix composites has always been challenges for manufacturing engineers due to the presence of hard and brittle reinforced particles. In this article, a new way of alternate application of electrical discharge grinding and abrasive grinding has been applied through the use of slotted grinding wheel. The developed machining process has been named as slotted electrical discharge abrasive grinding. The performances of slotted electrical discharge abrasive grinding process are tested on aluminum–silicon carbide–graphite (Al/SiC/Gr) metal matrix composite workpiece. The experiments were performed using one parameter at a time approach considering the effect of current, pulse on-time, pulse off-time, wheel speed and grit number on material removal rate and average surface roughness. It has been found that current ranges from 3 to 15 A and wheel speed ranges from 700 to 1300 r/min are more appropriate for machining of Al/SiC/Gr composite material within the ranges of selected parameters.

scholarly journals Experimental investigations and multi criteria optimization during machining of A356/WC MMCs using EDM

2022 ◽  
Vol 11 (2) ◽  
pp. 147-158
Author(s):  
Akash Singh ◽  
Karan Kumar ◽  
K. Gnana Sundari ◽  
Rishitosh Ranjan ◽  
B. Surekha
Keyword(s):  
Smart Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Casting Process ◽  
Stir Casting ◽  
Functionally Graded ◽  
Machining Process ◽  
Experimental Investigations ◽  
Process Factors ◽  
Pulse On Time

In the current paper, the authors are intended to manufacture the aluminum based metal matrix composite (MMC) employing the stir casting process. Further, the fabricated composite sample is investigated for machining characteristics during the die sink electrical discharge machining process (EDM). EDM is most commonly employed to satisfy the special needs of industry such as developing deep holes and complex contours from high strength materials such as composites, alloys, smart materials, and functionally graded materials. In the current study A356 and 4%, tungsten carbide (WC) powder are considered as matrix and strengthening materials respectively to fabricate the MMCs. During the machining activity, the input factors like discharge current (Ip), Voltage (Vg), Pulse On-Time (Ton), and flushing pressure (P) are optimized for achieving optimum surface roughness (SR), Tool Wear Rate (TWR) and Material Removal Rate (MRR). To estimate the ideal set of process factors grey regression analysis (GRA) is used. From the results, it was observed that the GRA is found to perform better than the RSM.

scholarly journals Experimental Study and Parameter Optimization of Hybrid Electrical Discharge Machining

2018 ◽  
Vol 7 (3.12) ◽  
pp. 1161
Author(s):  
Nishant Kumar Singh ◽  
Sandeep Agrawal ◽  
Rajvardhan . ◽  
Yashvir Singh
Keyword(s):  
Electrical Discharge ◽  
Oil And Gas ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Electrode Gap ◽  
Workpiece Material ◽  
Hybrid Machining Process ◽  
Pulse On Time

Hard materials cannot be machined effectively by the individual machining process. In order to machine workpiece made from hard and stiff materials effectively a concept of Hybrid machining process (HMP) is originated. The HMP is an integration of two or more machining process to get the advantage of each individual process. HMP is used to machine  This study focuses on evolving a novel process using both oil and gas as dielectrics to analyse the effect on tool wear rate (TWR) and material removal rate (MRR). The flow of compressed gas through eccentric-hole rotating tool improved the debris removal from inter-electrode gap, hence it improve the flushing competence of the machining process. In this experimental investigation, the workpiece material is Al-20% SiC metal matrix composite (MMC) and the electrode material is copper. The experiments were conducted following the Taguchi method of design experiments. The effect of various machining parameters on MRR and TWR has been studied. The optimization of process parameter has also been done. The results of TWR and MRR are analysed using S/N ratio, ANOVA and main effect plots. The experimental results, revels that discharge current, gap voltage and pulse on time significantly affected MRR, and TWR. The experimental inference reveal that provision of compressed air through eccentric hole rotary tool has a positive effect on machinability of electrical discharge machining (EDM) process.  

Optimization of Electro-Discharge Diamond Surface Grinding Process Parameters with Multiple Performance Characteristics of Ti-6Al-4V Using Grey-Taguchi Approach

2012 ◽  
Vol 622-623 ◽  
pp. 14-18
Author(s):  
Manoj Modi ◽  
G. Agarwal
Keyword(s):  
Process Parameters ◽  
Wheel Speed ◽  
Performance Characteristics ◽  
Surface Grinding ◽  
Machining Process ◽  
Duty Factor ◽  
Diamond Surface ◽  
Taguchi Approach ◽  
Pulse On Time ◽  
Grey Taguchi

The present paper reports the optimization of process parameters in hybrid machining process (Electro-Discharge Diamond Surface Grinding) of Ti-6Al-4V with multiple performance characteristics using the combination of Grey Relational Analysis (GRA) and Taguchi approach. The various input process parameters in this work are wheel speed (RPM), duty factor, current (ampere) and pulse on-time (µs). In this research work nine experiments have been conducted according to the Taguchi’s L9orthogonal array on in-house-designed & fabricated EDDSG set-up. The machining parameters wheel speed (S), duty factor (DF), current (I) and pulse on-time (Ton) are optimized with consideration of multiple performance characteristics such as material removal rate (MRR) and average surface roughness (Ra). The confirmation experimental results show that combined Grey-Taguchi approach enhances the machining performance in EDDSG of Ti-6Al-4V.

Micro-Machining of Glass Using Electrochemical Discharge Assisted Cutting

2016 ◽  
Author(s):  
Baoyang Jiang ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Geometric Accuracy ◽  
Machine Material ◽  
Hybrid Machining ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Hybrid Machining Process

Glass is a hard-to-machine material with vast industrial application. Electrochemical discharge machining (ECDM) is a non-traditional machining technology that has shown potential for effective glass machining. However, ECDM has not been widely used in industry despite being studied for over a decade. Major challenges of ECDM include limited machinable depth and low material removal rate. In this paper, an innovative hybrid machining process combining ECDM and traditional cutting is presented, namely electrochemical discharge assisted cutting. The material removal rate of the hybrid ECDM process is significantly higher than conventional processes. Experimental results are presented to prove the feasibility and capability of the process. Discussion concentrates on the improvement of geometric accuracy and surface integrity through experimentation.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Optimization of turn-milling process in roughing and finishing regimes: Trade-off between productivity, cutting force and surface integrity

2021 ◽  
pp. 095440892199851
Author(s):  
Ebrahim Hosseini ◽  
Shafiqur Rehman ◽  
Ashkan Alimoradi
Keyword(s):  
Cutting Force ◽  
Desirability Function ◽  
Milling Process ◽  
Machining Process ◽  
Hybrid Machining ◽  
Trade Off ◽  
Hybrid Machining Process ◽  
Process Factors ◽  
Turn Milling ◽  
Selection Of

Turn-milling is a hybrid machining process which used benefits of interrupted cutting for proceeding of round bars. However, number of controllable parameters in the hybrid process is numerous that makes optimizing the process complicated. In the present study, an optimization work has been proposed to investigate the trade-off between production rate and cutting force in roughing regime as well surface roughness and tensile residual stress in finishing regime. Number of 43 experiments based on response surface methodology was designed and carried out to gather required data for development of quadratic empirical models. Then, the adequacy and importance of process factors were analyzed using analysis of variances. Finally, desirability function was used to optimize the process in rough and finish machining regimes. The obtained results showed that selection of eccentricity and cutter speed at their maximum working range can effectively enhance the quality characteristics in both the roughing and finishing regimes.

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