A Study of Machining Parameters during Electrical Discharge Machining of Steel by a Rotary Copper Electrode

2009 ◽  
Vol 83-86 ◽  
pp. 756-763 ◽  
Author(s):  
P.S. Satsangi ◽  
K.D. Chattopadhyay
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Parameters ◽  
Electrical Parameters ◽  
Peak Current ◽  
Machining Characteristics

The use of thermo-electric source of energy, as in electrical discharge machining (EDM), has greatly helped in machining all types of electrically conductive materials being used in different industrial applications. The present work investigates the different machining characteristics during electrical discharge machining on EN-8 steel with a rotary copper electrode. The effects of three independent machining parameters viz. peak current, pulse on time and rotational speed of tool electrode are chosen as variables for evaluating the output parameters such as metal removal rate, surface finish of work piece. The research focuses on developing empirical models for prediction of metal removal rate and surface finish during rotary electrical discharge machining process with the help of input parameters. The models are developed using linear regression analysis by applying logarithmic data transformation of non-linear equation. Analysis of results using partial and multiple correlation analysis reveals that electrical parameters have more significant effect than the non-electrical parameters on the machining characteristics during electrical discharge machining by a rotary electrode. Furthermore, when high MRR is criterion, high peak current and low RPM with low pulse duration produces better output; whereas, and when smooth surface finish is criterion, low peak current and low RPM with high pulse duration produces better output. In addition, the predictions based on the above developed models are verified with extra experiments and are found to be in good agreement with the experimental verifications.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

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. 

Removal of Defective Layer after Electrical Discharge Machining

2019 ◽  
Vol 973 ◽  
pp. 157-160
Author(s):  
Stanislav A. Mozgov ◽  
Yuriy A. Morgunov ◽  
Boris P. Saushkin
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Work Piece ◽  
Machining Parameters ◽  
Electrode Gap ◽  
Machining Time ◽  
Defective Layer

This study investigates the possibility of electrochemical removal of the defective layer formed on the surface of the product after its electrical discharge machining. A set of experiments was conducted in different electrolytes based on aqueous and aqueous-organic solvents. The experiments were to trace the influence of such settings of electrochemical machining as current density, electrolyte pumping speed, electrolyte temperature, and an electrode gap upon both the dynamics of metal removal and surface quality. Morphology of the obtained surface was examined by an Olympus BX-51Microscope. The dynamics of removing material (stock) from the work piece was inspected. Appropriate adjustments were made to the machining parameters during the machining of 65G steels, and a preferred composition was selected for the working medium. A sufficient design for production tools was proposed. Pitting corrosion was discovered on the surface of the samples in all studied modes of electrolysis. It was observed that switching from aqueous electrolyte to aqueous-organic electrolyte gave lower material removal rate and longer machining time accordingly. At the same time, a reduction in surface roughness was visualized, together with smaller pits and lower density of their distribution. The obtained results may be applied in operation design for electrochemical machining of steels with relatively high carbon contents.

Investigation of RC Type Electrical Discharge Machining on ASSAB 618 Steel Using Copper Electrode

2013 ◽  
Vol 315 ◽  
pp. 30-34
Author(s):  
Muhammad Zulhisham Ahmed Zaki ◽  
M. Azuddin
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Energy Output ◽  
Electrode Wear ◽  
Discharge Energy ◽  
Rc Circuit

This paper presents the investigation on Electrical Discharge Machining (EDM) on ASSAB 618 steel using copper electrode. The sparking power was generated using Resistor Capacitor (RC) Circuit and not usual Transistor Pulse Generator Circuit. The performance of the electrodes in the EDM RC circuit was evaluated based on the achieved surface roughness with respect to material removal rate (MRR) and electrode wear ratio (EWR). In this study, investigations have been conducted with surface finish at different discharge energy output. It was found that the surface characteristics are dependent mostly on the discharge energy during machining. The fine finish electrical discharge machining requires minimization of the discharge energy supplied into the gap. In addition, the surface finish was found to be influenced greatly by the electrical and thermal properties of the electrode material.

scholarly journals Studi tentang Pengaruh Parameter Pemesinan dan Luas Penampang Bidang Potong terhadap Sifat Mampu Mesin baja AISI 1045 pada Pemesinan dengan EDM

2019 ◽  
Vol 1 (2) ◽  
pp. 59
Author(s):  
Hudiyo Firmanto ◽  
Susila Candra ◽  
Thomas Widiyatmoko
Keyword(s):  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Processes ◽  
Aisi 1045 ◽  
Pulse On Time ◽  
1045 Steel

To optimize machining processes in Electrical Discharge Machining (EDM) on a certain machining area, it is required to control its machining parameters such as electrical current (I) and pulse on time (Ton). This research aims to study the effect of machining parameters on electrode wear (EW) and metal removal rate (MRR) in EDM processes. It also attempts to investigate the taper effect in a hole machining by using EDM. To study the influence of machining area, several electrode diameters are employed, i.e. 10 mm, 12 mm and 20 mm. Experiment is performed on AISI 1045 steel by using copper electrode. The result shows that Ton and I influences EW and MRR in an opposite way. It also reveals that larger diameter electrode tends to decrease the ratio of EW and MRR. To obtain an optimum machining with smaller taper efect, it is recommended to use Ton between 700 msec to 1700 msec. With those Ton values, the optimum condition is given by I value of 6 Amp.

An integrated evolutionary approach for modelling and optimization of wire electrical discharge machining

2011 ◽  
Vol 225 (4) ◽  
pp. 549-567
Author(s):  
D Kondayya ◽  
A Gopala Krishna
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Evolutionary Approach ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Wedm Process ◽  
Modelling And Optimization

This paper presents an application of an integrated evolutionary approach for modelling and optimization of a wire electrical discharge machining (WEDM) process. The proposed methodology consists of two parts. In the first part, a novel application of genetic programming (GP) is proposed. GP is an evolutionary modelling algorithm which uses principles similar to genetic algorithms to model highly non-linear and complex processes, resulting in accurate and reliable models. Two important aspects of machining performance of WEDM, namely metal removal rate and surface roughness, are modelled based on experimental data using GP in terms of four prominent input variables. The effect of machining parameters on the performance measures is also reported. In the second part, as the chosen machining performances are opposite in nature, the problem under consideration is formulated as a multi-objective optimization problem and solved using an efficient evolutionary optimization algorithm, non-dominated sorting genetic algorithm-II (NSGA-II). The outcome of Pareto optimal solutions is presented. The work presents a fully fledged evolutionary approach for optimization of the process.

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 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.

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

scholarly journals Experimental Study on the Influence of Machining Conditions on the Quality of Electrical Discharge Machined Surfaces of aluminum alloy Al5052

Machines ◽  
2020 ◽  
Vol 8 (1) ◽  
pp. 12 ◽  
Author(s):  
Angelos P. Markopoulos ◽  
Emmanouil-Lazaros Papazoglou ◽  
Panagiotis Karmiris-Obratański
Keyword(s):  
Aluminum Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Parameters ◽  
Machining Processes ◽  
Machining Conditions ◽  
Pulse On Time ◽  
Machined Surfaces

Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed.

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