Multi-Objective Optimization of PMEDM Process of 90CrSi Alloy Steel for Minimum Electrode Wear Rate and Maximum Material Removal Rate with Silicon Carbide Powder

2021 ◽  
Vol 1018 ◽  
pp. 51-58
Author(s):  
Tran Thi Hong ◽  
Nguyen Van Cuong ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Silicon Carbide ◽  
Alloy Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Carbide Powder ◽  
Electrode Wear ◽  
Silicon Carbide Powder

This study aims to minimize electrode wear (EW) and maximize material removal rate (MRR) in powder mixed electrical discharge machining (PMEDM) process of 9CrSi alloy steel with silicon carbide powder. To achieve these objectives, Taguchi method and Grey Relational Analysis (GRA) are applied to optimize one two-level and four three-level PMEDM process parameters, including Ton, Toff, CP, IP and SV in eighteen experiments based on an orthogonal array L18 (21 and 43). Results have provided a set of optimal PMEDM process parameters in which Ton has the strongest effect on SW and MRR while that of CP is insignificant. The obtained minimum EW and maximum MRR have been verified and proven by a PMEDM experiment using optimal process parameters. The proposed method can be further applied to optimize other PMEDM process parameters for different objectives.

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.

Influence of Input Factors on Material Removal Rate in PMEDM Cylindrical Shaped Parts with Silicon Carbide Powder Suspended Dielectric

2020 ◽  
Vol 861 ◽  
pp. 129-135 ◽  
Author(s):  
Manh Cuong Nguyen ◽  
Luu Anh Tung ◽  
Bui Thanh Danh ◽  
Nguyen Van Cuong ◽  
Tran Thi Hong ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Five Factors ◽  
Cylindrical Parts ◽  
Pulse On Time ◽  
Pulse Off Time

This work is done to determine the effects of the input factors of powder mixed electrical discharge machining (PMEDM) process on the material removal rate (MRR). In the study, the workpiece is cylindrical parts made from 90CrSi alloy steel. Also, five factors containing the pulse on time Ton, the powder concentration Cp, the pulse off time Toff, the pulse current IP, and the server voltage SV were discovered to find their impact on MRR. In addition, the Taguchi method and ANOVA analysis were used to design experiment and analyze the results. In addition, an optimal model of the MRR was introduced. Also, the model has been well verified by comparison with testing, and so it can be used for further studies in the PMEDM process.

High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

Influence of Workpiece Shape on MRR and EWR in EDM of Steel

2014 ◽  
Vol 903 ◽  
pp. 51-55 ◽  
Author(s):  
Alexis Mouangue Nanimina ◽  
Ahmad Majdi Abdul Rani ◽  
Mohd Amri Lajis ◽  
Turnad Lenggo Ginta ◽  
T.V.V.L.N. Rao
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Electrode Wear ◽  
Wear Ratio ◽  
Flat Shape ◽  
Dielectric Flushing ◽  
Edm Process

Shape of workpiece, electrode orientation and flushing system play important role in electrical discharge machining (EDM) process. Low material removal rate and relatively high electrode wear ratio are some of the disadvantages of EDM process. This can be due to the flushing modes. Workpiece shape has a significant effect in effectiveness of dielectric flushing flow and orientation during EDM process. This research work is conducted to analyze the influence of various workpiece shapes. Square cavity, L shape, flat shape and U shape were machined with same cross-section electrode material. Test parameters are material removal rate (MRR) and electrode wear ratio (EWR). Experiment results show slight difference in MRR and EWR values for different shapes. U shape presents the highest MRR and the lowest EWR occurs in flat shape compared to cavity and L shapes. It can be concluded that flat and U shapes result in good EDM machining quality due to good dielectric flow and flushing conditions in the area of EDM machining.

scholarly journals Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

Crystals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1342
Author(s):  
Hongzhi Yan ◽  
Bakadiasa Djo Kabongo ◽  
Hongbing Zhou ◽  
Cheng Wu ◽  
Zhi Chen
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Volume ◽  
Wire Electrical Discharge Machining ◽  
Al Composite

With the properties of high specific strength, small thermal expansion and good abrasive resistance, the particle-reinforced aluminum matrix composite is widely used in the fields of aerospace, automobile and electronic communications, etc. However, the cutting performance of the particle-reinforced aluminum matrix composite is very poor due to severe tool wear and low machining efficiency. Wire electrical discharge machining has been proven to be a good machining method for conductive material with any hardness. Even so, the high-volume SiCp/Al content composite is still a difficult-to-machine material in wire electrical discharge machining due to the influence of insulative the SiC particle. The goal of this paper is to analyze the machining characteristics and find the optimal process parameters for the high-volume content (65 vol.%) SiCp/Al composite in wire electrical discharge machining. Experimental results show that the material removal method of the SiCp/Al composite includes sublimating, decomposing and particle shedding. The material removal rate is found to increase with the increasing pulse-on time, first increasing and then decreasing with the increasing pulse-off time, servo voltage, wire feed and wire tension. Pulse-on time and servo voltage are the dominant factors for surface roughness. In addition, the multi-objective optimization method of the nondominated neighbor immune algorithm is presented to optimize the process parameters for a fast material removal rate and low surface roughness. The optimized process parameters can increase the material removal rate by 34% and reduce the surface roughness by 6%. Furthermore, the effectiveness of the Pareto optimal solution is proven by the verified experiment.

scholarly journals A Study on Optimization of Process Parameters in Machining of Bronze using Wire-EDM

2021 ◽  
pp. 484-493
Author(s):  
Gajanan Kamble ◽  
Dr. N. Lakshamanaswamy ◽  
Gangadhara H S ◽  
Sharon Markus ◽  
N. Rajath
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time

Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf width were studied against the process parameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP). The machining parameters for wire EDM were optimized for achieving the combined objectives. As there are three input parameters 27 experiments is carried out and full factorial is used. Optimized parameters were found using (ANOVA) and the error percentage can be validated and parameter contribution for the Material removal rate (MRR) and Surface roughness were found.

Effect of Surfactant on EDM of Low Conductivity Reaction-Bonded Silicon Carbide

2016 ◽  
Vol 701 ◽  
pp. 107-111
Author(s):  
Muhammad Raziman Abdul Razak ◽  
Pay Jun Liew ◽  
Nur Izan Syahriah Hussein ◽  
Qumrul Ahsan
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Weight Percentage ◽  
Wear Ratio ◽  
Optimum Weight ◽  
Span 80

This work was focused on improving machining performance of reaction-bonded silicon carbide (RB-SiC) ceramic material using an electrical discharge machine (EDM) with the aid of surfactant. The changes of material removal rate, electrode wear ratio and surface roughness were investigated under two different surfactants, namely Span 20 and Span 80. The surfactant was mixed with carbon nanofiber (CNF) and EDM oil prior to the experiment. Then, the mixture was homogenized in an ultrasonic homogenizer for 35 minutes. In order to investigate the effect of surfactant, different weight percentages which is 0.4wt%, 0.6wt% and 0.8wt% of surfactant were used. The experimental results show that with the addition of Span 20 and Span 80, the electrode wear ratio was decreased with the increased of surfactants weight percentage. Surface finish also can be improved by adding surfactant in the dielectric fluid. The lowest surface roughness was achieved at a surfactant weight percentage of 0.4wt%. The optimum weight percentage for obtaining the highest material removal rate (MRR) was 0.6wt% for both surfactants. In comparison, CNF added with surfactant Span 80 was more effective to improve the machining efficiency of RB-SiC compared to surfactant Span 20, at the optimum weight percentage 0.6wt%.

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