Effects of Input Parameters on Electrode Wear Rate when EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 79-83
Author(s):  
Tran Thi Hong ◽  
Nguyen Van Cuong ◽  
Bui Thanh Danh ◽  
Nguyen Hong Linh ◽  
Le Hong Ky ◽  
...  
Keyword(s):  
Wear Rate ◽  
Electrical Discharge Machining ◽  
Manufacturing Cost ◽  
Electrode Wear ◽  
Electrode Wear Rate ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Selection Of

In electrical discharge machining (EDM) process, the selection of suitable EDM factors plays an important role since this can achieve the growing need for quality, minimizing manufacturing cost and time, and reducing electrode wear rate. This paper presents the effect of input factors on electrode wear rate (EWR) when machining cylindrical shaped parts made from 90CrSi steel and an optimization of these parameters. The input EDM parameters include the pulse on time, the pulse off time, the current, and the spark gap voltage. The Taguchi method with L27 was used for designing the experiment to gather data. Based on statistical analysis of experiment data, the impact of the input factors on the EWR was investigated. Moreover, the optimal input parameters were found by evaluating the S/N ratio in order to minimizing the EWR. This brings the significance in minimum surface roughness and high accuracy of machining elements.

Investigation the Electrode Wear Rate and Metal Removal Rate in EDM Process using Taguchi and ANOVA Method

2020 ◽  
Vol 38 (10A) ◽  
pp. 1504-1510
Author(s):  
Safaa K. Ghazi
Keyword(s):  
Wear Rate ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Metal Removal Rate ◽  
Electrode Wear Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The experimental work of this paper leads to electrical discharge machining (EDM). A system for machining in this process has been developed. Many parameters are studied such as current, pulse on-time, pulse off time of the machine. The main aim of this work is to calculate the metal removal rate (MRR) and electrode wear rate (EWR) using copper, electrodes when machining tool steel H13 specimens of a thickness (4mm). Different current rates are used ranging from (30, 42, and 54) Amp, pulse on-time ranging from (75, 100, and 125) and pulse off time ranging from (25, 50, and 75)   found that high current gives large electrode wear and metal removal rate and. The experiment design was by Taguchi Method. From an analysis of variance (ANOVA) the more active influence of input factors on the outputs is currently for metal removal rate (MRR) (58%) and electrode wear rate (EWR) (57).

Evaluating Influences of Input Parameters on Surface Roughness in Sinking EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 85-90
Author(s):  
Tran Thi Hong ◽  
Nguyen Anh Tuan ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Work Piece ◽  
Enabling Factors ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time ◽  
Optimum Input

The input parameters in the process of sinking Electrical Discharge Machining (EDM) are the essential enabling factors that need to be determined. In the present work, the influences of the EDM input parameters containing pulse on time (Ton), pulse off time (Toff), discharge current (IP), Server voltage (SV), work-piece diameter (dw) on the surface roughness (SR) in sinking EDM cylindrical shaped part of 9CrSi material were investigated. Taguchi technique and analysis of variance (ANOVA) have been used to identify the weight of EDM factors on SR. The results show that the impact level of Ton, Toff, IP, SP, and dw are 65.55%, 8.66%, 19.17%, 3.14%, and 0.76%, respectively. By analyzing the experimental results, optimum input parameters with the Ton of 6 ms, Toff of 30 ms, IP of 9A, SP of 3V, and dw of 10mm have been determined, that allow getting the best surface roughness.

Influence of Process Parameters on Electrode Wear in Electrical Discharge Machining Cylindrical Shaped Parts

2020 ◽  
Vol 853 ◽  
pp. 24-28
Author(s):  
Nguyen Van Cuong ◽  
Le Hong Ky ◽  
Tran Thi Hong ◽  
Tran Thanh Hoang ◽  
Manh Cuong Nguyen ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Input Parameter ◽  
Electrode Wear ◽  
Influence Of Process Parameters ◽  
Optimization Study ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper introduces an optimization study on electrode wear when electrical discharge machining (EDM) cylindrical shaped parts made from 90CrSi. In the study, the experiments were performed and analyzed by using Taguchi method. The input parameters of the experiments were the pulse on time, the pulse off time, the current, and the server voltage. The effect of input parameters on the electrode wear were evaluated by analyzing variance. Also, the optimum values of the input parameter were proposed for getting the minimum electrode wear.

Multi-Objective Optimization of Surface Roughness and Electrode Wear in EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 59-64
Author(s):  
Le Hong Ky ◽  
Bui Thanh Danh ◽  
Nguyen Van Cuong ◽  
Nguyen Hong Linh ◽  
Tran Thi Hong ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Electrode Wear ◽  
Input Parameters ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Calculated Model ◽  
Off Time ◽  
Optimum Input

The purpose of this work is to find an optimal combination of the input parameters when electrical discharge machining (EDM) cylindrical shaped parts so that both the surface roughness and the electrode wear are minimum. In this study, four input parameters including the pulse on time, the pulse off time, the current, and the serve voltage were taken into account. Experimental plan was designed based on L9 orthogonal array. Also, Taguchi method and Grey Relational Analysis (GRA) were joined for solving the multiobjective optimization problem and to find optimum input parameters. Experiments with optimal input parameters were performed for proving the predicted model. The experimental results of the surface roughness and the electrode wear matched with the calculated model. This indicates the proposed models can be used for practice.

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

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.

Effect of Higher Peak Current and Pulse Duration on EWR of Copper Electrode when Electrical Discharge Machining (EDM) of Inconel 718

2013 ◽  
Vol 845 ◽  
pp. 945-949
Author(s):  
S. Ahmad ◽  
Mohd Amri Lajis
Keyword(s):  
Wear Rate ◽  
Pulse Duration ◽  
Electrode Surface ◽  
Inconel 718 ◽  
Copper Electrode ◽  
Work Piece ◽  
Electrode Wear ◽  
Peak Current ◽  
Electrode Wear Rate ◽  
Pulse On Time

In this work, the electrode wear rate (EWR) and electrode surface characteristic of copper electrode when EDM of Nickel Based Super Alloy, Inconel 718 at higher peak current and pulse duration were analyzed. Experiments were conducted using Inconel 718 as a work piece and copper as an electrode with a kerosene dielectric under different peak currents and pulse durations. Peak current, Ip within a range of 20A to 40A and pulse duration (or pulse on-time), ton within a range of 200μs to 400μs are selected as the main parameters. In this study, EWR were measured using digital weight balance (accuracy 0.01mg) and by using Scanning Electron Microscope (SEM), the surface texture of the electrode in order to evaluate the material deposited on the electrode surface. The results have shown that machining at a lowest peak current of 20A and highest pulse duration of 400μs yields the lowest electrode wear rate (EWR) of -0.01mm3/min. The pulse duration is significantly affecting the EWR. It also revealed that, the deposited of carbon and work piece material is occurred on the electrode surface for all machining conditions.

scholarly journals Surface Roughness Prediction for Steel 304 In Edm Using Response Graph Modeling

2018 ◽  
Vol 14 (4) ◽  
pp. 115-124 ◽  
Author(s):  
Shukry H. Aghdeab ◽  
Nareen Hafidh Obaeed ◽  
Marwa Qasim Ibraheem
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Applied Current ◽  
Graph Modeling ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technique for metals removing which is relied upon the basic fact that negligible tool force is produced during the machining process. Also, electrical discharge machining is used in manufacturing very hard materials that are electrically conductive. Regarding the electrical discharge machining procedure, the most significant factor of the cutting parameter is the surface roughness (Ra). Conventional try and error method is time consuming as well as high cost. The purpose of the present research is to develop a mathematical model using response graph modeling (RGM). The impact of various parameters such as (current, pulsation on time and pulsation off time) are studied on the surface roughness in the present research. 27 samples were run by using CNC-EDM machine which used for cutting steel 304 with dielectric solution of gas oil by supplied DC current values (10, 20, and 30A). Voltage of (140V) uses to cut 1.7mm thickness of the steel and use the copper electrode. The result from this work is useful to be implemented in industry to reduce the time and cost of Ra prediction. It is observed from response table and response graph that the applied current and pulse on time have the most influence parameters of surface roughness while pulse off time has less influence parameter on it. The supreme and least surface roughness, which is achieved from all the 27 experiments is (4.02 and 2.12µm), respectively. The qualitative assessment reveals that the surface roughness increases as the applied current and pulse on time increases

scholarly journals Influence of Electrode Material and EDM Parameters on Electrode Wear of AISI H13 Steel

2020 ◽  
Vol 7 (2) ◽  
pp. 13-18
Author(s):  
Mostafa Adel Abdullah ◽  
Nareen Hafidh Obaeed ◽  
Aseil Mohammed Radhi ◽  
Hiba Adil Ahmed
Keyword(s):  
Electrode Material ◽  
Electrical Discharge Machining ◽  
Diesel Oil ◽  
Electrode Wear ◽  
H13 Steel ◽  
Electrically Conducting ◽  
Aisi H13 Steel ◽  
Aisi H13 ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract: Electrical discharge machining (EDM) is a non-traditional process that uses the electrical spark discharge to machine electrically conducting materials for geometrically complex shapes or hard materials. In the current work, cupper and brass were used as the electrode material, and AISI H13 steel as the workpiece. Different input parameters were investigated namely: 20, 30, 40 A current, 50, 100, 150 μs pulse on time, and 1, 3, 6 mm gap. The workpiece thickness was fixed to 4 mm and the pulse off time was 25 μs. All EDM experiments were carried out in diesel oil and the voltage was 140 V. The results showed that the electrode wear decreased with increasing the pulse on time and gap and increased with increasing current for copper and brass electrode. The optimal conditions for minimum tool wear were: pulse on time 150 μs, current 20 A, and gap 6 mm for copper and brass electrodes. Electrode wear is minimum for copper at all parameter values compared to brass electrode.

scholarly journals Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (3A) ◽  
pp. 319-324
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that the model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected by HAZ with 67.219% contribution.

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