Parametric Study of Powder Mixed Electrical Discharge Machining and Mathematical Modeling of SiSiC Using Copper Electrode

2013 ◽  
Vol 845 ◽  
pp. 878-882 ◽  
Author(s):  
Abdul Azeez Aliyu ◽  
Musa Hamidon ◽  
Jafri M. Rohani
Keyword(s):  
Silicon Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Fractional Factorial ◽  
Confirmatory Test ◽  
Design Parameters ◽  
Dielectric Fluid ◽  
Pulse On Time

In recent years, the need for Silicon carbide (SiC) ceramic arises due to several industrial applications. However, the cost of machining such components is very high. Electrical discharge machining (EDM) serves as the most viable machining technique. In this study, optimum setting of sinking-EDM parameters and mathematical model of siliconized silicon carbide (SiSiC) using aluminum powder mixed dielectric fluid has been developed. Analysis of variance shows that, material removal rate (MRR) increases with high discharge current and low servo voltage, whereas tool wear ratio (TWR) and surface roughness (Ra) decreases with low current and pulse-on time. The effects of design parameters on the machining characteristics were investigated using fractional factorial (resolution V) technique. Confirmatory test was then carried out to validate the models developed.

OPTIMIZATION OF ELECTRICAL DISCHARGE MACHINING PARAMETERS OF SISIC THROUGH RESPONSE SURFACE METHODOLOGY

2016 ◽  
Vol 79 (1) ◽  
Author(s):  
Abdul Azeez Abdu Aliyu ◽  
Jafri Mohd Rohani ◽  
Ahmad Majdi Abdul Rani ◽  
Hamidon Musa
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Machining Parameters ◽  
Difficult Time ◽  
Pulse On Time

In recent years, researchers have demonstrated increases interest in studies involving silicon carbide (SiC) materials due to several industrial applications. Extreme hardness and high brittleness properties of SiC make the machining of such material very difficult, time consuming and costly. Electrical discharge machining (EDM) has been regarded as the most viable method for the machining of SiC. The mechanism of EDM process is complex. Researchers have acknowledged a challenge in generating a model that accurately describes the correlation between the input parameters and the responses. This paper reports the study on parametric optimization of siliconized silicon carbide (SiSiC) for the following quality responses; material removal rate (MRR), tool wear ratio (TWR) and surface roughness (Ra). The experiments were planned using Face centered central composite design. The models which related MRR, TWR and Ra with the most significant factors such as discharge current (Ip), pulse-on time (Ton), and servo voltage (Sv) were developed. In order to develop, improve and optimize the models response surface methodology (RSM) was used. Non-linear models were proposed for MRR and Ra while linear model was proposed for TWR. The margin of error between predicted and experimental values of MRR, TWR and Ra are found within 6.7, 5.6 and 2.5% respectively. Thus, the excellent reproducibility of this experimental study is confirmed, and the models developed for MRR, TWR and Ra are justified to be valid by the confirmation tests.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

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. 

scholarly journals Optimization of the Material Removal Rate and Electrode Wear Ratio in Electrical Discharge Machining of Reaction-bonded Silicon Carbide by Response Surface Methodology

2020 ◽  
Vol 9 (4) ◽  
pp. 2116-2120
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Hardness ◽  
Electrode Wear ◽  
Good Surface ◽  
Pulse On Time

Reaction-bonded silicon carbide (RB-SiC) is widely used as moulding dies material in many industries thanks to its excellent properties. Nevertheless, because of its high hardness and brittleness, it is extremely hard to be machined with high accuracy and good surface finish. Therefore, electrical discharge machining (EDM) has been chosen as an alternative method to machine the RB-SiC. In the present study, an experimental investigation has been conducted to optimize and validate the EDM parameters on the MRR and EWR of low conductivity RB-SiC in EDM. The new Cu – 1.0 wt. % CNF composite electrode that fabricated via powder metallurgy (PM) process was used as the electrode. The experiments were systematically conducted by face-cubic centre (FCC) approach of response surface methodology (RSM). The mathematical models for MRR and EWR were developed in this study. In addition, analysis of variance (ANOVA) was also figured out to check the significance of the models. Three experiments were conducted as the confirmation test to determine the error percentage of MRR and EWR. Based on the results, only 3.06% and 3.93% errors were determined for both MRR and EWR, respectively. The optimum conditions for multi responses (MRR and EWR) were found to be at a current of 6A, voltage of 22V, and pulse on-time of 12µs. The findings of this study provide an important reference to the manufacturing industries, especially mould and die industry.

scholarly journals Optimization and modeling of Electrical Discharge parameters on Machining of Stavax Steel

2020 ◽  
Vol 6 (11) ◽  
pp. 53-62
Author(s):  
P Srinivasa Rao and Prof. Eshwara Prasad Koorapati
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Linear Regression Analysis ◽  
Performance Characteristics ◽  
Dielectric Fluid ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This work focuses on the use of the Taguchi method in order to find out the optimized parameters of the process like discharge current, pulse on time and pulse off time on the machining features such as material removal rate(MRR), surface roughness(SR) & tool wear rate(TWR) on Stavax Steel by means of Electrical Discharge Machining(EDM). It is also intended to study the individual influence of parameters on the performance characteristics. The dielectric fluid circulating system is modified to conduct the experiments. The analysis of variance (ANOVA) is made to recognise the importance of parameters on the response. By using non-linear regression analysis the empirical models are developed in order to predict these performance characteristics and the confirmation test was conducted at the optimal parameters settings to check the optimum expected values of performance features. Detailed analysis by using ANOVA is done and came out with the findings as a pulse on time is the most significant process parameter, next is the discharge current and the insignificant parameter is the pulse off time. Machining surface morphology was studied and observed that crater size is large and deeper due to a large amount of metal is melted and vaporized at the optimum condition of MRR.

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 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.

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 Multi-Objective Optimization of Process Parameters for Powder Mixed Electrical Discharge Machining of Inconel X-750 Alloy Using Taguchi-Topsis Approach

2021 ◽  
Vol 71 (1) ◽  
pp. 1-18
Author(s):  
Basha Shaik Khadar ◽  
Raju M. V. Jagannadha ◽  
Kolli Murahari
Keyword(s):  
Boron Carbide ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

scholarly journals Multi-Objective Optimization of Wire Electrical Discharge Machining of AL 2124/SIC Composite

2019 ◽  
Vol 9 (1) ◽  
pp. 2155-2163
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Strength ◽  
Wire Electrical Discharge Machining ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Predicted Values ◽  
Pulse On Time ◽  
Pulse Off Time

The growing demand for the use of high strength to weight alloys in industries for manufacturing complex structures challenges the machinability of such advanced materials. In the present investigation, the machinability of SiC particle reinforced Al 2124 composite was studied on Wire electrical discharge machining (WEDM). The process parameters namely pulse on-time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV) were optimized by utilizing the central composite design layout. The output responses such as kerf and material removal rate (MRR) were studied in detail. The single and multi-objective optimization was studied for a combination effect using Derringer’s desirability approach and Genetic Algorithm (GA). The experimental and predicted values for each response were validated at the optimized condition. The experimental results were found in line with the predicted values. Multi objective optimization of kerf and MRR by GA showing better result compared to RSM.

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