Performance of Graphene Nanopowder with Deionised Water in EDM Process

This paper emphasises the effect of the surfactant in the PMEDM process. The preparation of nanofluid is done by mixing and sonicating thoroughly into the deionised water is discussed. The effect of varying the graphene nanopowder concentration into the dielectric is also discussed. Also, the effect of surfactant SDS and CTAB in the machining process is elaborated at 0.1 and 0.2g per 800ml concentration. MRR improved by 21.27% and roughness by 18.91% at 0.2g and 8µs, 2A and 50V in 800ml deionised water. SDS provide better MRR and low roughness compared to CTAB at higher peak current and higher pulse on time Simultaneously, the addition of surfactant into the dielectric medium reduces the performance of the EDM process. The MRR varies from 21mg/min at 0g graphene to 45mg/min at 0.2g and then 31.81mg/min at 0.2g with 0.1g SDS, 43mg/min at 0.2g SDS, 28.33mg/min at 0.1g CTAB and 30mg/min at 0.2g CTAB. Debris size also varies with the input parameters.

Experimental Investigation and Optimization of Electric Discharge Machining Process Parameters Using Grey-Fuzzy-Based Hybrid Techniques

Materials ◽

10.3390/ma14195820 ◽

2021 ◽

Vol 14 (19) ◽

pp. 5820

Author(s):

Ankit Sharma ◽

Vidyapati Kumar ◽

Atul Babbar ◽

Vikas Dhawan ◽

Ketan Kotecha ◽

...

Keyword(s):

Electrical Discharge Machining ◽

Removal Rate ◽

Machining Process ◽

Spheroidal Graphite ◽

Electrode Gap ◽

Peak Current ◽

Hybrid Techniques ◽

Input Parameters ◽

Pulse On Time ◽

Electrical discharge machining (EDM) has recently been shown to be one of the most successful unconventional machining methods for meeting the requirements of today’s manufacturing sector by producing complicated curved geometries in a broad variety of contemporary engineering materials. The machining efficiency of an EDM process during hexagonal hole formation on pearlitic Spheroidal Graphite (SG) iron 450/12 grade material was examined in this study utilizing peak current (I), pulse-on time (Ton), and inter-electrode gap (IEG) as input parameters. The responses, on the other hand, were the material removal rate (MRR) and overcut. During the experimental trials, the peak current ranged from 32 to 44 A, the pulse-on duration ranged from 30–120 s, and the inter-electrode gap ranged from 0.011 to 0.014 mm. Grey relational analysis (GRA) was interwoven with a fuzzy logic method to optimize the multi-objective technique that was explored in this EDM process. The effect of changing EDM process parameter values on responses was further investigated and statistically analyzed. Additionally, a response graph and response table were produced to determine the best parametric setting based on the calculated grey-fuzzy reasoning grade (GFRG). Furthermore, predictor regression models for response characteristics and GFRG were constructed, and a confirmation test was performed using randomly chosen input parameters to validate the generated models.

Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

International Journal of Engineering & Technology ◽

10.14419/ijet.v7i2.8.10316 ◽

2018 ◽

Vol 7 (2.8) ◽

pp. 10

Author(s):

A VS Ram Prasad ◽

Koona Ramji ◽

B Raghu Kumar

Keyword(s):

Surface Roughness ◽

Taguchi Method ◽

Process Parameters ◽

Optimization Technique ◽

Machining Process ◽

Machining Parameters ◽

Wire Edm ◽

Pulse On Time ◽

Pulse Off Time ◽

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.1393 ◽

2011 ◽

Vol 189-193 ◽

pp. 1393-1400 ◽

Cited By ~ 2

Author(s):

M.M. Rahman

Keyword(s):

Surface Roughness ◽

Wear Rate ◽

Process Parameters ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Machining Process ◽

Peak Current ◽

Long Pulse ◽

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

Study on the Influence of Metallic Powder in Near-Dry Electric Discharge Machining

Strojniški vestnik – Journal of Mechanical Engineering ◽

10.5545/sv-jme.2019.6475 ◽

2020 ◽

Vol 66 (4) ◽

pp. 243-253 ◽

Cited By ~ 1

Author(s):

Sanjay Sundriyal ◽

Vipin ◽

Ravinderjit Singh Walia

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Dielectric Medium ◽

Metallic Powder ◽

Machining Process ◽

Dry Electrical Discharge Machining

En 31 ◽

Edm Process ◽

Near-dry electrical discharge machining (ND-EDM) is an eco-friendly process. In this study, an approach has been made to make the machining process more efficient than ND-EDM with the addition of metallic powder with the dielectric medium to machine EN-31 die steel. Powdermixed near-dry EDM (PMND-EDM) has several advantages over the ND-EDM or conventional electrical discharge machining (EDM) process, such as a higher material removal rate (MRR), fine surface finish (Ra), sharp cutting edge, lesser recast layer, and lower deposition of debris. The output response variables are MRR, Ra, residual stress (RS) and micro-hardness (MH) of the machined surfaces. Further study of the workpiece was performed, and a comparative study was conducted between ND-EDM and PMND-EDM. In this proposed method of machining, the MRR, Ra, and MH increased by 17.85 %, 16.36 %, and 62.69 % while RS was reduced by 56.09 %.

Effect of the parameters in electromagnetic field assisted electric discharge machining

Journal of Physics Conference Series ◽

10.1088/1742-6596/2070/1/012236 ◽

2021 ◽

Vol 2070 (1) ◽

pp. 012236

Author(s):

S V Raut ◽

A Bongale ◽

S Kumar

Keyword(s):

Electromagnetic Field ◽

Circular Plate ◽

Electric Discharge ◽

Machining Process ◽

Maximum Effect ◽

Work Piece ◽

Input Parameters ◽

Neodymium Magnets ◽

Abstract The electric discharge machining is a non-conventional machining process, in which the spark is electric spark is generate in gap between the work piece and electrode. Due to heat generated by spark in between the workpiece and electrode, the material get vaporized from small area form workpiece and get cool down with the help of dielectric fluid. In present study low carbon mold steel use as a work piece and copper electrode is used. The electromagnetic field included in the process to analyze the effect of the input parameters on the machine response parameters like MRR and the surface roughness value (Ra). The study is done on EDM process with and without EMF by varying the input parameters Ton (μs) and keeping the other parameters constant (Toff (μs), Current (A) & Voltage (V)). The set of the neodymium magnets are used in the set up having 4500 gauss units. The circular plate is designed to hold the neodymium magnets nearer to the work piece using CATIA V5 version. 3D printer is used to fabricate the circular plate that holds the electromagnets precisely near to the area under spark to have a maximum effect of EMF in the EDM process. The experimentations shows that response parameter shows good output at pulse on time of 200 ms and 300 ms with and without EMF respectively.

Optimization of machining characteristics for EDM of different nickel-based alloys by embodying of fuzzy, grey relational and Taguchi technique

World Journal of Engineering ◽

10.1108/wje-07-2020-0262 ◽

2020 ◽

Vol 18 (1) ◽

pp. 23-36

Author(s):

Sahil Sharma ◽

Umesh Kumar Vates ◽

Amit Bansal

Keyword(s):

Inconel 718 ◽

Machining Process ◽

Simultaneous Optimization ◽

Inconel 625 ◽

Electrode Wear ◽

Peak Current ◽

Content Type ◽

Grey Relational ◽

Pulse On Time ◽

Machining Characteristics

Purpose In the current exploration, the machinability of three different nickel-based super-alloy materials (Inconel 625, Inconel 718 and Nimonic 90) was experimentally investigated by using a die-sinking electrical discharge machining (EDM). The effect of changing important input process parameters such as pulse on time (Ton), off time (Toff), peak current (Ip) and tool rotation (TR) was investigated to get optimum machining characteristics such as material removal rate, roughness, electrode wear rate and overcut. Design/methodology/approach Experimentation has been performed by using Taguchi L9 orthogonal design. An integrated route of fuzzy and grey relational analysis approach with Taguchi’s philosophy has been intended for the simultaneous optimization of machining output parameters. Findings The most approbatory factors for machining setting have been attained as: (Ton = 100 µs, Toff = 25 µs, Ip = 14 A, TR = 725 rpm) for machining of Inconel 625 and Inconel 718; and (Ton = 100 µs, Toff = 75 µs, Ip = 14 A, TR = 925 rpm) for machining of the Nimonic 90 material. Peak current has been observed as an overall influencing factor to achieve better machining process. Microstructural study through SEM has also been carried out to figure out the surface morphology for the EDMed Ni-based super alloys. Originality/value The proposed machining variables and methodology has never been presented for Nimonic 90 alloy on die-sinking EDM.

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

10.1177/0954405416673104 ◽

2016 ◽

Vol 232 (9) ◽

pp. 1603-1614 ◽

Cited By ~ 15

Author(s):

Vikas Gohil ◽

Yogesh M Puri

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Removal Rate ◽

Machining Process ◽

Machining Parameters ◽

Peak Current ◽

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

Study the Surface Characteristics of Cryogenically Treated Tool-Electrodes in Powder Mixed Electric Discharge Machining Process

Materials Science Forum ◽

10.4028/www.scientific.net/msf.808.19 ◽

2014 ◽

Vol 808 ◽

pp. 19-33 ◽

Cited By ~ 2

Author(s):

Sanjeev Kumar ◽

Rupinder Singh ◽

Ajay Batish ◽

T.P. Singh

Keyword(s):

Electric Discharge ◽

Surface Characteristics ◽

Machining Process ◽

Dielectric Fluid ◽

Tool Electrode ◽

Material Transfer ◽

Input Parameters ◽

The present experimental study has been focused to evaluate surface characteristics of cryogenically-treated (shallow/deep) tool-electrodes using powder mixed electric discharge machining. Due to the continuously growing demand of complex and precise parts, tool-electrodes have its own importance, because quality of the machined parts depends upon the surface quality of electrode. On the analogy, eighteen experiments were performed based on L18orthogonal array of Taguchi’s methodology, which consist eight input parameters. Analysis of variance (ANOVA) was employed to designate the level of significance of input parameters. Electrode material has maximum influence followed by the current and pulse on-time on electrode finish. The combination of optimum factor’s level of identified parameters was determined using Taguchi’s technique for single response. Confirmation experiments were conducted using suggested optimal parameters with its respective level to minimize the tool-electrode surface roughness. Surface characteristics of tool-electrodes were analyzed using Scanning Electron Microscope (SEM) and Energy Dispersive Spectrograph (EDS) followed by X-ray diffraction (XRD) on selected samples. The results exposed that significant material transfer from workpiece and powder mixed dielectric fluid in compound form on the tool surface.

Optimization of Machining Parameters in Rotary EDM Process Using Copper Tungsten Electrode

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.813-814.368 ◽

2015 ◽

Vol 813-814 ◽

pp. 368-375

Author(s):

Suddala Chandramouli ◽

Kesha Eswaraiah

Keyword(s):

Process Parameters ◽

Electric Discharge ◽

Removal Rate ◽

Machining Parameters ◽

Tungsten Electrode ◽

Input Parameters ◽

Pulse On Time ◽

Pulse Off Time ◽

Electrical Discharge Machining is a thermo-electric process and one of the advanced methods of machining. Most publications on the EDM process are directed towards non-rotational tools, but rotation of the tool provides a good flushing in the machining zone. In this study, the optimal setting of the process parameters on Rotary Electric Discharge machining (REDM) was determined. The important process parameters that have been selected are peak current, pulse on time, pulse off time and rotational speed of tool with output response as Material Removal Rate (MRR).Taguchi experimental design (L27 orthogonal array) was used to formulate the experimental layout and experiments were conducted on Hardened stainless steel machined with copper tungsten electrode. ANOVA method was used with the help of MINITAB 17 software to analysis the influence of input process parameters on the MRR using Rotary Electric Discharge Machining. The input parameters were optimized in order to obtain maximum MRR, The results of the present work revealed that proper selection of input parameters will play a significant role on MRR.

Correlation of Input Parameters with Tool Martial on the Output Parameters of Electrical Discharge Machining Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.994 ◽

2012 ◽

Vol 445 ◽

pp. 994-999 ◽

Cited By ~ 1

Author(s):

Mohammad Reza Shabgard ◽

Mirsadegh Seyedzavvar

Keyword(s):

Electrical Discharge ◽

Material Removal ◽

Pulse Current ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Tool Material ◽

Machining Process ◽

Process Stability ◽

Input Parameters ◽

This paper details the correlation between the input parameters with the tool material on the machining response in comparison of two different combinations of toolworkpiece material, namely copper-H13 and graphite-H13. The considered machining input parameters included pulse current and pulse on-time, and the investigated characteristics of the machining response were the material removal rate, tool wear, and surface roughness of the workpiece. Furthermore, differences in pulse shapes and process stability between the copper-H13 and graphite-H13 combinations were investigated.