Effects of Polymer Particles Suspending in Dielectric Fluid on Surface Roughness of EDM

2010 ◽  
Vol 97-101 ◽  
pp. 4146-4149 ◽  
Author(s):  
Yao Yang Tsai ◽  
Chih Kang Chang
Keyword(s):  
Molecular Weight ◽  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Silicone Oil ◽  
Dielectric Fluid ◽  
Polymer Particles ◽  
Machined Surface ◽  
Machining Speed ◽  
Pani Salt

Suspending powder in dielectric fluid of EDM (electrical discharge machining) has been developed to improve the quality of machined surface recently. The used powders are usually Al, Cu, Cr and so on metal powder because conductive particle can increase the spark gap and improve surface roughness of machined surface. Semi-conductive powder, Si is also utilized for the sake of increasing machining speed. This paper presents a new tryout to suspend polymer particles in the dielectric fluid of EDM. Experimental results show that the EDM process with suspending polymer particles still can be carried out but its surface roughness is not so good in conventional EDM oil. However the conventional EDM oil was taken the replace of silicone oil, suspending polyaniline (PANI-emer) of high molecular weight (Mw~65000) has finer improvement even better than using Si powder. Its surface roughness achieves less than Ra 0.2μm at low concentration and will be decreased gradually with increasing the concentration of PANI-emer (Mw~65000). The surface roughness is Ra 0.14μm when the powders concentration is 10g/l. Even for different type of polyaniline shows different machining characteristics. The surfaces roughness becomes worse when the concentration of low molecular weight PANI-emer (Mw~20000) is higher. An electric-conductive PANI-salt powder has a rapid decrease of surface roughness with increasing its concentration than other materials.

An Investigation into Surface Roughness of EDM Using Soft Particles Suspension in Silicone Oil

2008 ◽  
Vol 389-390 ◽  
pp. 430-435 ◽  
Author(s):  
Yao Yang Tsai ◽  
Chih Kang Chang
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Silicone Oil ◽  
Experimental Result ◽  
Dielectric Fluid ◽  
Polymer Particles ◽  
Hard Particles ◽  
Soft Particles ◽  
Edm Process

Electrical discharge machining (EDM) is an excellent technology to machining die and mold, but it is uneasy to obtain mirror-like surface. Powder-Mixed dielectric electrical discharge machining (PMD-EDM) is the innovative technology of EDM process, which can improve the quality of machined surface and applied in EDM finish machining now. The powder is usually hard particles, such as Al, Cu, Cr and Si in PMD-EDM. This paper presents a new research of PMD-EDM with suspending soft particles and abrasive grits in the dielectric fluid, especially focus on surface roughness. Experimental result shows the EDM process with polymer particles and abrasive grits can be carried out in silicone oil and the surface roughness has the finer improvement when increasing the rotation speed. Also, the effect of hard particles suspending in dielectric fluid are also discussed and compared. The surface roughness using polymer particles and abrasive in specific condition was better than only hard particles in silicone oil. Moreover, mixing abrasive and polymer in EDM can perform the polishing process.

Optimization of machining parameters in chromium-additive mixed electrical discharge machining of the AA7075/5%B4C composite

2021 ◽  
pp. 095440892110317
Author(s):  
Vineet Dubey ◽  
Anuj K Sharma ◽  
Balbir Singh
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Condition ◽  
Dielectric Fluid ◽  
Optimum Process ◽  
Machining Parameters ◽  
Machined Surface ◽  
Pulse On Time ◽  
Pulse Off Time

The present study establishes the optimum process condition for additive mixed electrical discharge machining of Al7075–5%B4Cp metal matrix composite by performing experimental investigation. The suspension of chromium particles in a dielectric fluid is used as an additive. The input process parameters selected for experimentation are specifically pulse on-time, gap voltage, pulse off-time and peak current, for analysing their influence on wear of the tool along with surface roughness of the composite. Comparative study of the machined surface is done by analysing microstructures, cracks and recast layers formed at different settings of input parameters using a scanning electron microscope. Rise in amount of current and pulse on-time led to increased height of the recast layer generated on the surface of the machined workpiece. Furthermore, a confirmatory experiment was performed at the optimal setting. The result revealed an error of 5.5% and 7.5% between experimental and predicted value of tool wear rate and surface roughness.

scholarly journals Investigation into effects/Investigating the effects of titanium powder concentrations mixed in dielectric fluid on material machining removal and surface roughness of SKD61 steel after electrical discharge machining by reverse electrode polarity

2015 ◽  
Vol 18 (2) ◽  
pp. 43-51
Author(s):  
Long Tien Banh ◽  
Cuong Ngo ◽  
Phan Huu Nguyen
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Material Removal ◽  
Titanium Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Electrode Polarity ◽  
Edm Process

Electrical discharge machining (EDM) has found widespread applications in tool , mold and aerospace industries. Therefore, enhancement of the quality of the EDM process has become a major research concern. In this paper, the effect of various titanium powder concentrations on the Material Removal Rate (MRR), tool wear rate (TWR), surface roughness (Ra) in powder mixed electrical discharge machining (PMEDM) have been studied. The workpiece is SKD61steel and electrode made from copper with reverse polarity were used in experimental study. The results showed that titanium powder mixed into the dielectric fluid of EDM can enhance MRR without increasing TWR and Ra.

A Study on Influence of Input Parameters on Surface Roughness in PMEDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 65-70
Author(s):  
Tran Thi Hong ◽  
Bui Thanh Danh ◽  
Nguyen Van Cuong ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Improve Quality ◽  
Input Parameters ◽  
Edm Process ◽  
Optimum Input

In electrical discharge machining (EDM) powder material can be mixed into the dielectric fluid to improve quality of machining surface of components. Therefore, finding suitable input parameters of this process becomes an important task. This paper presents a methodology to find the optimum input factors of the EDM process when adding nanosilicon carbide powder into the dielectric fluid for processing cylindrical shaped parts. In this research, the Taguchi method was used for experiment design in order to investigate the effect of the input parameters on the surface roughness. Also, optimum input factors for minimum surface roughness (RS) was proposed. The result from the deviation of SRbetween the analysis and the experiment demonstrates that the optimum input parameters are helpful to predict the value of surface roughness. Therefore, this can increase the economic and technical effectiveness in EDM process.

Surfactant and graphite powder–assisted electrical discharge machining of titanium alloy

2016 ◽  
Vol 231 (4) ◽  
pp. 641-657 ◽  
Author(s):  
Murahari Kolli ◽  
Adepu Kumar
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Recast Layer ◽  
Dielectric Fluid ◽  
Recast Layer Thickness

Surfactant and graphite powder–assisted electrical discharge machining was proposed and experiments were performed on titanium alloy in this investigation. Analysis was carried out to observe changes in dielectric fluid behaviour, material removal rate, surface roughness, recast layer thickness, surface topography and energy-dispersive X-ray spectroscopy. It was found out that the addition of surfactant to dielectric fluid (electrical discharge machining oil + graphite powder) improved the material removal rate and surface roughness. It was noticed to have reduced the recast layer thickness and agglomeration of graphite and sediment particles. Biface material migrations between the electrode and the workpiece surface were identified, and migration behaviour was powerfully inhibited by the mixing of surfactant. Surfactant added into dielectric fluid played an important role in the discharge gap, which increased the conductivity, and suspended debris particles in dielectric fluid reduced the abnormal discharge conditions of the machine and improved the overall machining efficiency.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

scholarly journals Parametric optimization of wire cut electrical discharge machining

2014 ◽  
Vol 3 (2) ◽  
pp. 212
Author(s):  
M. Durairaj ◽  
A.K.S. Ansari ◽  
M. H. Gauthamkumar
Keyword(s):  
Surface Roughness ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Fluid Pressure ◽  
Performance Criteria ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire

2014 ◽  
Vol 592-594 ◽  
pp. 416-420 ◽  
Author(s):  
Singaravelu D. Lenin ◽  
A. Uthirapathi ◽  
Ramana Reddy P.S. Venkata ◽  
Muthukannan Durai Selvam
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Brass Wire

The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

scholarly journals Surface Roughness Analysis of H13 Steel during Electrical Discharge Machining Process Using Cu–TiC Sintered Electrode

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 5943
Author(s):  
Arminder Singh Walia ◽  
Vineet Srivastava ◽  
Mayank Garg ◽  
Nalin Somani ◽  
Nitin Kumar Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
H13 Steel ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Semi Empirical

In electrical discharge machining (EDM), the machined surface quality can be affected by the excessive temperature generation during the machining process. To achieve a longer life of the finished part, the machined surface quality plays a key role in maintaining its overall integrity. Surface roughness is an important quality evaluation of a material’s surface that has considerable influence on mechanical performance of the material. Herein, a sintered cermet tooltip with 75% copper and 25% titanium carbide was used as tool electrode for processing H13 steel. The experiments have been performed to investigate the effects of EDM parameters on the machined surface roughness. The findings show that, as the pulse current, pulse length, and pulse interval are increased, the surface roughness tends to rise. The most significant determinant for surface roughness was found to be pulse current. A semi-empirical surface roughness model was created using the characteristics of the EDM technique. Buckingham’s theorem was used to develop a semi-empirical surface roughness prediction model. The semi-empirical model’s predictions were in good agreement with the experimental studies, and the built empirical model based on physical features of the cermet tooltip was tested using dimensional analysis.

scholarly journals 302 Evaluation of Machined Surface Quality of Long Fiber FRM by Electrical Discharge Machining

2000 ◽  
Vol 2000.53 (0) ◽  
pp. 49-50
Author(s):  
Rikio HIKIJI ◽  
Yoshihiro KAWANO ◽  
Koji ABURADA ◽  
Masakazu HARADA ◽  
Minoru ARAI
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machined Surface ◽  
Machined Surface Quality
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