Effects of Electrical Discharge Energy on Machining Performance of Sintered NdFeB Magnet

2009 ◽  
Vol 620-622 ◽  
pp. 711-714 ◽  
Author(s):  
Li Li ◽  
Guang Ming Yuan ◽  
Zong Wei Niu ◽  
Rong Guo Hou
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Discharge Energy ◽  
Machining Performance ◽  
Ndfeb Magnet ◽  
Machined Surface ◽  
Micro Cracks ◽  
Ndfeb Permanent Magnet

Sintered NdFeB permanent magnet is widely used in many areas because of its excellent magnet property. In this study, the machining parameters of electrical discharge machining (EDM) are varied to study the effects of electrical discharge energy on material removal rate and surface roughness of NdFeB magnet. Moreover, the micro-cracks on the machined surface induced by EDM are also examined. The experimental results reveal that the MRR increases with the electrical discharge energy. The number of surface cracks on the machined surface increases with the enhancement of discharge energy Thus, using EDM process to machine sintered NdFeB magnet depends on setting the machining parameters to prevent surface crack.

Surface Integrity of Sintered NdFeB Permanent Magnet after EDM

2012 ◽  
Vol 503-504 ◽  
pp. 27-30
Author(s):  
Li Li ◽  
Zong Wei Niu ◽  
Feng Shi Yin ◽  
Yuan Yong Liu
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Discharge Energy ◽  
Ndfeb Magnet ◽  
Machined Surface ◽  
Micro Cracks ◽  
Ndfeb Permanent Magnet ◽  
Edm Process

In this study, the machining parameters of electrical discharge machining (EDM) are varied to study the effects of electrical discharge energy on material removal rate and surface roughness of NdFeB magnet. Moreover, the micro-cracks on the machined surface induced by EDM are also examined. The experimental results reveal that the MRR increases with the electrical discharge energy. The surface cracks on the machined surface are more serious when the discharge energy is higher. Thus, using EDM process to machine sintered NdFeB magnet depends on setting the machining parameters to prevent surface crack.

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.

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

Electrical Discharge Machining of SiC and Gr Reinforced 6061-T6 Aluminum Alloy Hybrid Composite Fabricated by Friction Stir Processing

2013 ◽  
Author(s):  
Murahari Kolli ◽  
Devaraj Aruri ◽  
Kumar Adepu
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Machining Performance ◽  
Friction Stir

Aluminum based hybrid composites are advanced materials having the properties of high hardness, superior wear resistance, strength, high elevated temperature and low thermal expansion coefficient. These hybrid composites are widely used in industries like automobile and aerospace. In this present paper 6061-T6 Aluminum alloy reinforced with SiC and Gr particles, hybrid composites are fabricated by using Friction stir processing (FSP) technique. It prevents the further development of hybrid composites for machining by nonconventional methods like water jet and laser cutting process. Electrical discharge machining (EDM) is used for machining the complex shapes of the material. This paper presents an overview of EDM studies conducted on the Al-SiC/Gr hybrid composites using a copper electrode in EDM. The EDM experiment machining parameters such as the dielectric fluid, peak current, pulse on, pulse off times are changed to explore their effects on machining performance, material removal rate (MRR), Tool wear rate (TWR), and surface roughness (SR). It is observed that the MRR and SR of the Al-SiC/Gr hybrid composites increase with an increase in the current.

Evaluation of Electrical Discharge Machining Performance on Al (6351)–SiC–B4C Composite

2019 ◽  
pp. 109-124
Author(s):  
Uthayakumar M. ◽  
Suresh Kumar S. ◽  
Thirumalai Kumaran S. ◽  
Parameswaran P.
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machined Surface ◽  
Output Performance ◽  
B4c Particles

Electrical discharge machining (EDM) process is a non-conventional machining process used for the material which are difficult to machine. In this research work, an attempt has been made to determine the influence of Boron Carbide (B4C) particles on the machinablity of the Al (6351) alloy reinforced with 5 wt. % Silicon Carbide (SiC) Metal Matrix Composite (MMC) through EDM. Influence of machining parameters such as pulse current (I), pulse on time (Ton), duty factor (τ), and gap voltage (V) on affecting the output performance characteristics namely Electrode Wear Ratio (EWR), Surface Roughness (SR) and Power Consumption (PC) which are studied. The result shows that the addition of B4C particles significantly affects the machinablity of the composite, with a contribution of 1.6% on EWR, 3.5% on SR and 19.8% on PC. The crater, recast layer formation, and Heat Affected Zone (HAZ) in the machined surface of the composite are also reported in detail.

Turning by electrical discharge machining: A review

2016 ◽  
Vol 231 (2) ◽  
pp. 195-208 ◽  
Author(s):  
Vikas Gohil ◽  
YM Puri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Free Form ◽  
Machining Parameters ◽  
Machining Performance ◽  
Complex Shapes ◽  
Discharge Machine ◽  
Future Direction

Turning by electrical discharge machining is an emerging area of research. Generally, wire-cut electrical discharge machining is used for turning because it is not concerned with electrode tooling cost. The process variant die-sinking electrical discharge machining can also be effectively used to generate free-form cylindrical geometries on difficult-to-cut materials with complex shapes at both macro and micro levels. The machining performance of electric discharge machine is defined and influenced by its process parameters, which significantly affects production rate and the quality of machined component. Thus, it is very important to select machining parameters and their levels cautiously in order to improve the outcome of the process. In this article, the authors have reviewed the research work carried out in the area of electrical discharge turning in the last decade for the improvement of material removal rate, surface integrity and roundness. In this review, various techniques reported by electrical discharge machining researchers on turning have been categorised in different electrical discharge machining variants. The article also discussed the future direction of research work in the same area.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

scholarly journals A study on Electrical Discharge Machining of Titanium Grade2 with experimental and theoretical analysis

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Emmanouil L. Papazoglou ◽  
Panagiotis Karmiris-Obratański ◽  
Beata Leszczyńska-Madej ◽  
Angelos P. Markopoulos
Keyword(s):  
Power Distribution ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Process ◽  
Heat Transfer Analysis ◽  
Machining Parameters ◽  
Machining Performance ◽  
Plasma Flushing Efficiency

AbstractTitanium alloys, due to their unique properties, are utilized in numerous modern high-end applications. Electrical Discharge Machining (EDM) is a non-conventional machining process, commonly used in machining of hard-to-cut materials. The current paper, presents an experimental study regarding the machining of Titanium Grade2 with EDM, coupled with the development of a simulation model. The machining performance indexes of Material Removal Rate, Tool Wear Ratio, and Average White Layer Thickness were measured and calculated for different pulse-on currents and pulse-on times. Moreover, the developed model that integrates a heat transfer analysis with deformed geometry, allows to estimate the power distribution between the electrode and the workpiece, as well as the Plasma Flushing Efficiency, giving an insight view of the process. Finally, by employing the Response Surface Methodology, educed regression models that correlate the machining parameters with the corresponding results, while for all the aforementioned indexes, ANOVA was performed.

An integrated evolutionary approach for modelling and optimization of wire electrical discharge machining

2011 ◽  
Vol 225 (4) ◽  
pp. 549-567
Author(s):  
D Kondayya ◽  
A Gopala Krishna
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Evolutionary Approach ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Wedm Process ◽  
Modelling And Optimization

This paper presents an application of an integrated evolutionary approach for modelling and optimization of a wire electrical discharge machining (WEDM) process. The proposed methodology consists of two parts. In the first part, a novel application of genetic programming (GP) is proposed. GP is an evolutionary modelling algorithm which uses principles similar to genetic algorithms to model highly non-linear and complex processes, resulting in accurate and reliable models. Two important aspects of machining performance of WEDM, namely metal removal rate and surface roughness, are modelled based on experimental data using GP in terms of four prominent input variables. The effect of machining parameters on the performance measures is also reported. In the second part, as the chosen machining performances are opposite in nature, the problem under consideration is formulated as a multi-objective optimization problem and solved using an efficient evolutionary optimization algorithm, non-dominated sorting genetic algorithm-II (NSGA-II). The outcome of Pareto optimal solutions is presented. The work presents a fully fledged evolutionary approach for optimization of the process.

Effect of Ultrasonic Vibration of Tool on Electrical Discharge Machining of Sintered NdFeB Magnet

2009 ◽  
Vol 407-408 ◽  
pp. 628-631
Author(s):  
Li Li ◽  
Zong Wei Niu ◽  
Guang Ming Yuan
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Ndfeb Magnet ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Versus Peak ◽  
Pulse On Time

Sintered NdFeB magnet is widely used in many areas because of its excellent magnet. This paper studies the effect of ultrasonic vibration of tool on electrical discharge machining of it. Experiments were carried out on self-made equipment and material removal rate(MRR) against pulse-on time, MRR versus peak current and machined surface results with and without ultrasonic employment were analyzed. Results show that MRR of the ultrasonic assisted electro-discharge machining would be up to five times higher than MRR of the conventional EDM for small pulse durations and low discharge currents. The machined surface of US/EDM is finer than EDM because of less arcing and short circuit pulses. There are less cracks on the surface.

Sign in / Sign up

Export Citation Format

Share Document