Correlation of Input Parameters with Tool Martial on the Output Parameters of Electrical Discharge Machining Process

2012 ◽  
Vol 445 ◽  
pp. 994-999 ◽  
Author(s):  
Mohammad Reza Shabgard ◽  
Mirsadegh Seyedzavvar
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Material ◽  
Machining Process ◽  
Process Stability ◽  
Input Parameters ◽  
Pulse On Time

This paper details the correlation between the input parameters with the tool material on the machining response in comparison of two different combinations of toolworkpiece material, namely copper-H13 and graphite-H13. The considered machining input parameters included pulse current and pulse on-time, and the investigated characteristics of the machining response were the material removal rate, tool wear, and surface roughness of the workpiece. Furthermore, differences in pulse shapes and process stability between the copper-H13 and graphite-H13 combinations were investigated.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics

2019 ◽  
Vol 233 (14) ◽  
pp. 2515-2530 ◽  
Author(s):  
R Rajeswari ◽  
MS Shunmugam
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Machining Process ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Pulse On Time

Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a consequential reduction in cycle time. Powder mix and ultrasonic assistance are employed in the electrical discharge machining process to create gap conditions favoring material removal. In the present work, experiments are carried out on hardened D3 die steel using full-factorial design based on three levels of voltage, current and pulse on time. The gap phenomena in graphite powder-mixed and ultrasonic-assisted rough electrical discharge machining are studied using a detailed analysis of pulse shapes and their characteristic trains. Two new parameters, namely, energy expended over a second ( E) and performance factor ( PF) denoting the ratio of energy associated with sparks to total discharge energy, bring out gap conditions effectively. In comparison with the conventional electrical discharge machining for the selected condition, it is seen that the graphite powder mixed in the dielectric enhances the material removal rate by 20.8% with E of 215 J and PF of 0.227, while these values are 179.8 J and 0.076 for ultrasonic-assisted electrical discharge machining with marginal reduction of 3.9%. Cross-sectional images of workpieces also reveal the influence of electrical discharge machining conditions on the machined surface. The proposed approach can be extended to different powder mix and ultrasonic conditions to identify condition favoring higher material removal.

Influence of Tool Material on the Electrical Discharge Machining of AISI H13 Tool Steel

2012 ◽  
Vol 445 ◽  
pp. 988-993 ◽  
Author(s):  
Mirsadegh Seyedzavvar ◽  
Mohammad Reza Shabgard
Keyword(s):  
Tool Steel ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Tool Material ◽  
Machining Process ◽  
H13 Tool Steel ◽  
Aisi H13 ◽  
Pulse On Time ◽  
Aisi H13 Tool Steel

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of tool material on the characteristics of Electrical Discharge Machining process of AISI H13 tool steel. The studied process characteristics included the tool wear ration and thickness of the white layer on the workpiece after the EDM process. The experiments carried out under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The results of this study could be utilized to choice a set of pulse on-time and pulse current according to the outcomes that suit the requirements of tool-workpiece combination processed by the EDM.

scholarly journals Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 164
Author(s):  
Panagiotis Karmiris-Obratański ◽  
Emmanouil L. Papazoglou ◽  
Beata Leszczyńska-Madej ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Tool Material ◽  
Machining Process ◽  
Machining Performance ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are widely used in high-end applications owing to their unique intrinsic characteristics. Nonetheless, they have low machinability. The current paper includes an experimental examination of EDM’s Ti-6Al-4V ELI (Extra Low Interstitials through controlled interstitial element levels) process utilizing a graphite electrode. The pulse-on current (IP) and pulse-on time (Ton) were used as control parameters, and machining performance was measured in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The Surface Roughness (SR) was estimated based on the mean roughness (SRa) and maximum peak to valley height (SRz), while, the EDMed surfaces were also examined using optical and SEM microscopy and cross-sections to determine the Average White Layer Thickness (AWLT). Finally, for the indices above, Analysis of Variance (ANOVA) was conducted, whilst semi-empirical correlations for the MRR and TMRR were given using the Response Surface Method (RSM). The results show that the pulse-on time is the most significant parameter of the machining process that may increase the MRR up to 354%. Pulse-on current and pulse-on time are shown to have an impact on the surface integrity of the finished product. Furthermore, statistics, SEM, and EDX images on material removal efficiency and tool wear rate are offered to support the core causes of surface and sub-surface damage. The average microhardness of the White Layer (WL) is 1786 HV.

scholarly journals Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

2021 ◽  
Vol 9 (10) ◽  
pp. 989-997
Author(s):  
Rouhan Rafiq
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

Abstract: One of the important non-traditional machining processes is Wire Electrical Discharge Machining, used for machining difficult to machine materials like composites and inter-metallic materials. WEDM involves complex physical and chemical process including heating and cooling. Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact resistance are increasing. The WEDM satisfy the present demands of the manufacturing industries such as better finish, low tolerance, higher production rate, miniaturization etc. The consistent quality of parts being machined in WEDM is difficult because the process parameters cannot be controlled effectively. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researcher and practicing engineers for a very long time. The objective of the present study was to experimentally investigate the effects of various Wire Electrical Discharge Machining variables on Surface Roughness and Material Removal Rate of AISI 1045 using ANOVA method. Taguchi’s L18 Orthogonal Array was used to conduct experiments, which correspond to randomly chosen different combination of process parameters: wire type, pulse on time, pulse off time, peak current, servo voltage, wire feed rate, flushing pressure each to be varied in three different levels. The surface roughness and material removal rate were selected as output responses for the present investigation. The effect of all the input parameters on the output responses have been analyzed using analysis of variance (ANOVA). The effect of variation in input parameters has been studied on the output responses. Plots of S/N ratio have been used to determine the best relationship between the responses and the input parameters. In other words, the optimum set of input parameters for minimum surface roughness and maximum material removal rate were determined. It has been found that wire type, pulse on time are most significant factors for surface roughness and wire type, pulse on time, pulse off time, wire feed rate are most significant factors for material removal rate. Keywords: Input Parameters, Wire Electric Discharge Machining, ANOVA, Taguchi

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.

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.

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.

Fabrication and experimental investigation of magnetic field assisted powder mixed electrical discharge machining on machining of aluminum 6061 alloy

2019 ◽  
Vol 233 (12) ◽  
pp. 2283-2291 ◽  
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Pulse On Time

Magnetic field assisted powder mixed electrical discharge machining is a hybrid machining process with suitable modification in electrical discharge machining combining the use of magnetic field and fine powder in the dielectric fluid. Aluminum 6061 alloy has found highly significance for the advanced industries like automotive, aerospace, electrical, marine, food processing and chemical due to good corrosion resistance, high strength-to-weight ratio, ease of weldability. In this present work, magnetic field assisted powder mixed electrical discharge machining setup was fabricated and experiments were performed using one factor at a time approach for aluminum 6061 alloy. The individual effect of machining parameters namely, peak current, pulse on time, pulse off time, powder concentration and magnetic field on material removal rate and tool wear rate was investigated. The effect of peak current was found to be dominant on material removal rate and tool wear rate followed by pulse on time, powder concentration and magnetic field. Increase in material removal rate and tool wear rate was observed with increase in peak current, pulse on time and a decrease in pulse off time, whereas, for material removal rate increases and tool wear rate decreases up to the certain value and follow the reverse trend with an increase in powder concentration. Material removal rate was increased and tool wear rate was decreased with increase in magnetic field.

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

2020 ◽  
Vol 235 (1-2) ◽  
pp. 125-133
Author(s):  
Omer Eyercioglu ◽  
Kursad Gov
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Magnesium Content ◽  
Machining Process ◽  
Electrode Wear ◽  
Ti Alloy ◽  
Ti Alloys ◽  
Mg Content

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

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