Electrical Discharge Machining Characteristics of ECAP Copper Electrode

2019 ◽  
Vol 969 ◽  
pp. 738-743
Author(s):  
R. Gopal ◽  
K.R. Thangadurai ◽  
K. Thirunavukkarasu
Keyword(s):  
Equal Channel Angular Pressing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Copper Electrode ◽  
Machining Process ◽  
Electrode Wear ◽  
Angular Pressing ◽  
Machining Characteristics ◽  
Bare Copper

Enormous research work has done on the electrode wear in spark erosion machining such as hybrid electrical discharge machining process, introducing various methods such as ultrasonic vibration in electrode, rotating the electrode, developing new electrode material (alloys and composites) and surface coated electrode etc,. Equal Channel Angular pressing is one such technique which makes tool material harder through grain refinement and ultimately enhances the tool life. The work material is AISI H13. For this research work, two copper electrodes are prepared, out of which one copper electrode has undergone equal channel angular pressing process. The most influencing parameters of spark machining like current, pulse on time and pulses off time are chosen for this study. The experiments are conducted using bare copper electrode and equal channel angular pressed copper electrode based on the box Behnken approach. The observations are analyzed for the machining characteristics in terms of rate of machining, rate of tool erosion and surface coarseness. Finally, it is found that ECAP processed copper electrode has lesser wear rate and better surface finish than bare copper electrode.

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.

Deep Hole of AISI P20 Mold Steel Material by Electrical Discharge Machining

2014 ◽  
Vol 590 ◽  
pp. 244-248
Author(s):  
Jamkamon Kamonpong ◽  
Pichai Janmanee
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Side Surface ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Steel Material ◽  
Suitable Parameter ◽  
Aisi P20 ◽  
Off Time

This research aimed to study the machining efficiency of AISI P20 steel by Electrical Discharge Machining (EDM) using rod copper electrode to machining material by 50 mm depth of machining was mainly assessed from Materials Removal Rate (MRR) and Electrode Wear Ratio (EWR). From the experiment designed to use Taguchi technique of data analysis and suitable parameter prediction, the highest MRR was at on-time of 150 μs, off-time of 2 μs and electric current level was at 15 A or 0.25 A/mm2. Predicted value was at 19.2395 mm3/min which was equal to real experiment, showing Materials Removal Rate of 19.647 mm3/min (with error of 2.12 percent) .Moreover, it was found that gap would increase with the size of electrode and depth of machining caused by movement of particles removed from side surface of electrode, which cause micro sparks at the side of the material workpiece.

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

2020 ◽  
Vol 235 (1-2) ◽  
pp. 125-133
Author(s):  
Omer Eyercioglu ◽  
Kursad Gov
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Magnesium Content ◽  
Machining Process ◽  
Electrode Wear ◽  
Ti Alloy ◽  
Ti Alloys ◽  
Mg Content

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

Multi Response Optimization of Electrical Discharge Machining Process Parameters Using Sintered Copper Electrode

2012 ◽  
Vol 622-623 ◽  
pp. 19-24
Author(s):  
P. Balasubramanian ◽  
Thiyagarajan Senthilvelan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Sintered Copper ◽  
Response Optimization ◽  
Electric Pressure ◽  
Pulse On Time

In this study, input parameters of Electrical Discharge machining (EDM) process have been optimised for two different materials EN-8 and Die steel-D3 were machined by using sintered copper electrode. Analysis of variance (ANOVA) was applied to study the influences of process parameters viz: - peak current, pulse on time, di-electric pressure and diameter of electrode on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) for both materials. Response surface methodology (RSM) has been applied to optimise the multi responses in order to get maximum MRR, minimum TWR and minimum SR. Furthermore, mathematical model has been formulated to estimate the corresponding output responses for both work pieces. It has been observed that compared to EN 8 material, the MRR value is low and TWR is high for D3 material. However the SR value is marginally lower than obtained in EN8.R2 value is above 0.90 for both work pieces.

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

Electrode Tool Wear at Electrical Discharge Machining

2012 ◽  
Vol 504-506 ◽  
pp. 1189-1194 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Margareta Coteaţă ◽  
Lorelei Gherman ◽  
...  
Keyword(s):  
Cross Section ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Experimental Tests ◽  
Machining Process ◽  
Electrode Wear ◽  
Electrical Discharges ◽  
Workpiece Material ◽  
Electrode Tool ◽  
Theoretical Considerations

As consequence of the development of electrical discharge machining process, the electrode is affected by wear; knowing the evolution of the electrode wear, a better estimation of its service life is possible. It is expected that the electrode wear depends on the energy of the electrical discharges and the mass of the electrode. It is known also that the nature of the workpiece material exerts influence on the evolution of the electrode wearing process. In the paper, some theoretical considerations are used to highlight the above mentioned aspects. A set of experimental tests was designed and developed in order to highlight the influence exerted by the nature of the workpiece material and by the size of the cross section of the electrode, respectively, on the electrode wear. Empirical mathematical models corresponding to the evolution of the electrode wear were established.

The surface integrity of ultra-fine grain steel, Electrical discharge machined using Iso-pulse and resistance–capacitance-type generator

2020 ◽  
Vol 234 (4) ◽  
pp. 564-573
Author(s):  
Mohammad S Mahdieh
Keyword(s):  
Surface Integrity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Strength ◽  
Functional Method ◽  
Machining Process ◽  
Machining Parameters ◽  
Fine Grained ◽  
Hardness Tester ◽  
Angular Pressing

Ultra-fine grained materials with high strength and low weight are eventually considered to be used in industries. To produce ultra-fine grained materials, equal channel angular pressing is a functional method, imposing severe plastic deformation on the workpiece. Electrical discharge machining is an indispensable process in manufacturing industrial parts with high accuracy and precision. However, electrical discharge machining has thermo-physical consequences, damaging the surface layers of the workpiece. On the other hand, the ultra-fine grained materials are thermodynamically unstable and tend to microstructural evolution. Thus, electrical discharge machining process affects the ultra-fine grained materials more than coarse grain materials. In this study, the effects of electrical discharge machining on the ultra-fine grained steel were investigated and the undesirable influences of the electrical discharge machining were diminished by adjusting the electrical discharge machining parameters. The ultra-fine grained steel samples were electrical discharge machined in two methods including Iso-pulse (roughing mode and finishing mode) and with resistance–capacitance-type generator. The surface integrity parameters, including thickness and microstructure of the recast layer and heat-affected zone, the cracks density and hardness, which for all three types of samples, were investigated by scanning electron microscopy, optical microscopy, X-ray diffraction technique, and micro-hardness tester. The results show that electrical discharge machining with resistance–capacitance-type generator has the minimum effects on the surface integrity of the ultra-fine grained samples because of the different material removal mechanism of resistance–capacitance-type electrical discharge machining.

Study on electrical discharge machining for cemented carbide with non-flammable dielectric liquid: Influence of form of oxygen supplied to dielectric liquid on machining

2017 ◽  
Vol 232 (4) ◽  
pp. 568-577 ◽  
Author(s):  
Masahiro Yoshida ◽  
Yuu Ishii ◽  
Takemi Ueda
Keyword(s):  
Hydrogen Peroxide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dielectric Liquid ◽  
Cemented Carbide ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Speed ◽  
Machining Characteristics ◽  
Oil Type

One of the problems faced in the finish electrical discharge machining of cemented carbide is the slow machining speed due to frequent abnormal discharges and concentrated discharge. To resolve this problem, in this study, attempts were made to supply oxygen to oil-type non-flammable dielectric liquid used in finish electrical discharge machining. First, the effects of the form of the oxygen when it is supplied to the dielectric liquid were investigated. As a result, it was found that when oxygen is supplied to the machining gap in the microbubble state, machining is not affected at all. When dissolved in the dielectric liquid and supplied, machining speed was seen to improve. Next, machining experiments were conducted, varying the percentage of 35 wt% hydrogen peroxide water mixed with the dielectric liquid to change the amount of oxygen in the dielectric liquid. As a result, the following were clarified. (1) The machining speed was six times faster than normal dielectric liquid when 15 wt% of oxygen was mixed; (2) at this time, the tool electrode wear had decreased to one-fifth that of normal dielectric liquid; (3) the surface roughness obtained was below Ra 1 µm regardless of the mixed percentage of hydrogen peroxide water; and (4) better machining characteristics were obtained when the workpiece was set as the positive electrode.

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