Experimental Investigation on Manufacturing and Environmental Aspects of Electrical Discharge Machining Process Using Graphite Electrode

2012 ◽  
Vol 433-440 ◽  
pp. 655-659
Author(s):  
S. Thiyagarajan ◽  
S.P. Sivapirakasam ◽  
Jose Mathew ◽  
M. Surianarayanan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Electrode ◽  
Environmental Aspects ◽  
Influence Of Process Parameters ◽  
Peak Current ◽  
Aerosol Emission

This paper presents a study on the influence of process parameters on the manufacturing and environmental aspects of die sinking electrical discharge machining process using graphite as the tool electrode. This investigation included peak current, pulse duration, dielectric level and flushing pressure as the input parameters and aerosol emission rate, material removal rate and tool wear rate as the output parameters. The experiments were planned according to the Taguchi L9 orthogonal array. The effects of process parameters on the output responses were analyzed using main effect plots. Peak current was the most significant process parameter. A discussion on the optimization of process parameters is also presented in this paper.

scholarly journals Effect of Peak Current on Material Removal Rate for Electrical Discharge Machining of Non-Conductive Al2O3 Ceramic

2013 ◽  
Vol 845 ◽  
pp. 730-734 ◽  
Author(s):  
M.A. Moudood ◽  
A. Sabur ◽  
Mohammad Yeakub Ali ◽  
I.H. Jaafar
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Machining Process ◽  
Tool Electrode ◽  
Peak Current ◽  
Assisting Electrode

Electrical discharge machining (EDM) is a non-conventional machining process where materials are removed by the thermal energy exerted from series of electrical sparks. This process is applied for machining of non-conductive alumina (Al2O3). The workpiece is covered with the adhesive copper foil to initiate the initial spark between the workpiece and the tool electrode. A pyrolytic carbon (PyC) layer is generated on workpiece surface by dissociating kerosene dielectric after the machining of initial copper assisting electrode (AE) layer. In this study, experiments were performed by varying the peak current and keeping other parameters constant in order to investigate the effect of peak current on material removal rate (MRR) in EDM of Al2O3. The results showed that the lowest and the highest values of peak current were 1.1 A and 1.3 A, respectively. Material cannot be removed due to insufficient PyC layer generation for any values of peak current less than 1.1 A or more than 1.3 A. From the results, it is also observed that the MRR is increased when higher peak current values are used. MRR was found to be 0.052 mm3/min at peak current 1.1 A and it was found to be 0.132 mm3/min at peak current 1.3 A.

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.

Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy

2015 ◽  
Vol 231 (6) ◽  
pp. 956-970 ◽  
Author(s):  
Neeraj Sharma ◽  
Tilak Raj ◽  
Kamal Kumar Jangra
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Influence Of Process Parameters ◽  
Work Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Response Variables

NiTi is a shape memory alloy, mostly employed in cardiovascular stents, orthopedic implants, orthodontic wires, micro-electromechanical systems and so on. The effective and net shape machining of NiTi is very critical for excellent response of this material in medical and other applications. The present experimental work on wire electrical discharge machining process identifies the influence of process parameters that affect the cutting rate, dimensional shift and surface roughness while machining of porous nickel–titanium (Ni40Ti60) alloy. Porous Ni40Ti60 alloy was produced in-house using powder metallurgy technique. Response surface methodology–based central composite rotatable design has been used for the planning of experiments on wire electrical discharge machining. Empirical relations have been developed between the process parameters (pulse on-time, pulse off-time, servo voltage and peak current) and response variables. Desirability approach has been used for optimizing the three response variables simultaneously. Confirmation experiments were also performed at the optimized settings and reflect a close agreement between the predicted and experimental values (percentage error varies from −6.13% to +6.85%). Using wire electrical discharge machining, NiTi alloy can be machined easily and successfully in single-cutting operation, but after the first cut in wire electrical discharge machining, a surface projection appears on work surface which is the unmachined material on work surface.

Finite Element Analysis of Material Removal Rate in Electrical Discharge Machining Process and its Comparison with Experiments

2014 ◽  
Vol 984-985 ◽  
pp. 48-55
Author(s):  
Sibakanta Sahu ◽  
Swarup Kumar Nayak ◽  
Saipad Sahu ◽  
Pallavi Chaudhury
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Experimental Result ◽  
Discharge Pulse

The non-convectional machining processes are those using thermal source of energy for the material removal. Among them Electrical discharge machining (EDM) or spark erosion machining is most important one. The important process parameters in this technique are discharge pulse on time, discharge pulse off time current and gap voltage. The values of these parameters significantly affect such machining outputs as material removal rate. In this paper, an axisymmetric thermo-physical finite element model for the simulation of single sparks machining during electrical discharge machining (EDM) process is exhibited. The model has been solved using ANSYS 11.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties has been used to investigate the temperature distribution. Material removal rate was calculated for multi-discharge machining by taking into considerations the number of pulses. Comparison, analyzation of the theoretical result and experimental result by considering the same process parameters has been done, and the result is highly agreed between the experimental and theoretical value so the model is validated.

The Mechanism of Ultrasonic Vibration Improving MRR in UEDM in Gas

2004 ◽  
Vol 471-472 ◽  
pp. 741-745 ◽  
Author(s):  
Qin He Zhang ◽  
Ru Du ◽  
Jian Hua Zhang ◽  
J.Y. Yang ◽  
Sheng Feng Ren
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Electrode ◽  
Metallic Liquid ◽  
Liquid Drops ◽  
Effective Discharge ◽  
Gas Medium

A new machining method, ultrasonic vibration aided electrical discharge machining (UEDM) in gas, is proposed in this paper. It is shown that electrical discharge machining with ultrasonic vibration aid can be achieved well in gas medium. In the process of UEDM in gas, the tool electrode is formed to be thin-walled pipe, high pressure gas medium is supplied from inside, and ultrasonic vibration is applied to workpiece. The property of ultrasonic is introduced. The same to other sound waves, ultrasonic have the characteristics of reflecting, refracting, intervening and resonance. The mechanism of elastic pole keeping in resonance with ultrasonic transferring from one end to the other end is explained with characteristics of ultrasonic. During the process of UEDM in gas, ultrasonic vibration of workpiece can improve the machining process. The theories of ultrasonic vibration increasing materials removal rate (MRR) are introduced. One theory is that the adhere strength between the metallic liquid drops and workpiece is not enough for the accelerative vibration, so metallic liquid drops will be ejected off easily. Another theory is that ultrasonic vibration increases the number of the effective discharge.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

scholarly journals Grey Relational Analysis of EDM of Ti6Al4V using TiC/Cu Composite Tool Electrode Made with Nano and Micron Sized Particles

2019 ◽  
Vol 9 (1) ◽  
pp. 6154-6162
Keyword(s):  
Process Parameters ◽  
Grey Relational Analysis ◽  
Optimum Combination ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
Dominant Factor ◽  
Tool Electrode ◽  
Peak Current ◽  
Relational Analysis ◽  
Grey Relational

This paper covers the use of Taguchi based grey relational analysis in EDM process. The analysis is used to determine an optimum combination of process parameters, which involves individual and simultaneous improvement of surface roughness (SR) and the micro hardness (MH) of Ti6Al4V alloy in electric discharge machining (EDM). The tool used in the machining process is TiC/Cu powder metallurgy (P/M) electrode. Taguchi’s L18 mixed orthogonal array is used to plan experimentations which includes the machine tool and electrode parameters as the study parameters. The analysis of variance (ANOVA) for grey relational grade showed that particle size EDM electrode was the most dominant factor (64.13%) followed by peak current (7.41%) in influencing surface quality of EDMed Ti6Al4V alloy. Whereas, peak current is the most influential parameter while evaluating the individual responses of SR and MH. Finally, the optimum combination of process parameters was validated by confirmation experiments that considerably improved the multiple quality characteristics simultaneously.

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