scholarly journals Investigation on Material Removal Rate and Surface Finish in Electrical Discharge Machining of AA 6061-B4C Composite Material

2021 ◽  
Vol 23 (12) ◽  
pp. 224-235
Author(s):  
N. Ethiraj ◽  
◽  
T. Sivabalan ◽  
Saibal Chatterjee ◽  
Seeramsetti Mahesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time

One of the non-conventional techniques of metal removal manufacturing processes is electrical discharge machining (EDM). The objective of this paper is to prepare a composite material consisting of a matrix of Aluminium AA 6061 alloy and Boron carbide (B4C) as reinforcement and investigate the output responses, the material removal rate, the quality of the surface formed and overcut during EDM process. The process parameters discharge current, Pulse on time and Duty cycle along with the weight % of B4C are considered for investigation to investigate the output responses such as material removal rate, surface roughness and overcut. From the experimental results, it is observed that the weight % of reinforcement has more influence on the material removal rate. The parameters discharge current and pulse-on-time plays an important role in reducing the surface roughness and overcut. Microstructural study helps in understanding the effect of process parameters on the output responses.

scholarly journals Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

2021 ◽  
Vol 9 (10) ◽  
pp. 989-997
Author(s):  
Rouhan Rafiq
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

Abstract: One of the important non-traditional machining processes is Wire Electrical Discharge Machining, used for machining difficult to machine materials like composites and inter-metallic materials. WEDM involves complex physical and chemical process including heating and cooling. Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact resistance are increasing. The WEDM satisfy the present demands of the manufacturing industries such as better finish, low tolerance, higher production rate, miniaturization etc. The consistent quality of parts being machined in WEDM is difficult because the process parameters cannot be controlled effectively. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researcher and practicing engineers for a very long time. The objective of the present study was to experimentally investigate the effects of various Wire Electrical Discharge Machining variables on Surface Roughness and Material Removal Rate of AISI 1045 using ANOVA method. Taguchi’s L18 Orthogonal Array was used to conduct experiments, which correspond to randomly chosen different combination of process parameters: wire type, pulse on time, pulse off time, peak current, servo voltage, wire feed rate, flushing pressure each to be varied in three different levels. The surface roughness and material removal rate were selected as output responses for the present investigation. The effect of all the input parameters on the output responses have been analyzed using analysis of variance (ANOVA). The effect of variation in input parameters has been studied on the output responses. Plots of S/N ratio have been used to determine the best relationship between the responses and the input parameters. In other words, the optimum set of input parameters for minimum surface roughness and maximum material removal rate were determined. It has been found that wire type, pulse on time are most significant factors for surface roughness and wire type, pulse on time, pulse off time, wire feed rate are most significant factors for material removal rate. Keywords: Input Parameters, Wire Electric Discharge Machining, ANOVA, Taguchi

Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
G. Ramanan ◽  
R. Elangovan
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

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.

scholarly journals Optimization of EDM Process Parameter for MRR and SR of 17- 4 PH Steel Using Response Surface Methodology

2018 ◽  
Vol 1 (2) ◽  
Author(s):  
SHUBHRATA NAGPAL
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Pulse On Time

In the present work, an attempt has been made for material removal rate and surface roughness by response surface optimization techniques in Electrical discharge machining. Electrical discharge machining, commonly known as EDM, is a process that is used to remove metal through the action of an electrical discharge of short duration and high current density between the work piece and too. This work presents the results of a mathematical investigation carried out to the effects of machining parameters such as current, pulse on time, pulse off time and lift time on material removal rate and surface roughness in electrical discharge machining of 17-4 PH steel by using copper electrode. Response surface methodology and ANOVA techniques are used for data analysis to solve the multi-response optimization. To validate the optimum levels of the parameter, confirmation run was performed by setting the parameters at optimum levels. Material Removal Rate during the process has been taken as productivity estimate with the objective to maximize it. With an intention of minimizing surface roughness is been considered as most important output parameter. It is found that the good agreement of that current is most significant parameter for material removal rate and less for surface roughness followed by pulse on time and lift time.

scholarly journals Performance Evaluation of SiC Powder Mixed Electrical Discharge Machining: A Case of Wire Cut Mode with Re-Circulating Molybdenum Wire

2021 ◽  
Author(s):  
Muhammad Qaiser Saleem ◽  
Maham Naqvi ◽  
Sarmad Ali Khan ◽  
Nadeem Ahmad Mufti ◽  
Kashif Ishfaq
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Molybdenum Wire ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Wire Wear

Abstract Review of the available literature on powder mixed electrical discharge machining (PMEDM) indicates, that most of the research has been done for “die sinking machining mode” whereas the “wire cut machining mode” has not received due attention despite being an important process variant. This work employs Silicon Carbide (SiC) powder mixed dielectric fluid for machining of AISI D2 in “wire cut” mode with re-circulating molybdenum wire (an economic and chemically stable proposition as tool). The effect of five process parameters (powder concentration, peak current, pulse on time, nozzle flushing pressure and stand-off distance) have been evaluated on surface roughness, kerf width, material removal rate and wire wear ratio using Taguchi’s approach. It is found that for surface roughness, higher current and low to moderate concentration levels (2 to 4g/l) deteriorate surface quality; higher values of pressure and stand-off distance are also seen to adversely affect it. For material removal rate, pulse on time as well as its interactions with powder concentration and current, are statistically significant. A higher pulse on with smaller and moderate powder concentrations (2g/l and 4g/l) reduces MRR. For wire wear ratio, current is the sole significant factor (PCR of ~ 65%). SEM analysis of the machined workpiece for the maximum MRR condition quantifies recast layer as ~ 19microns. An indirect comparison with the reported values for non-powdered EDM process indicates that for the similar wire (molybdenum), the use of SiC powder maintains the surface roughness and kerf values, for a much harder D2 material used in this work.

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.

scholarly journals The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

2020 ◽  
Vol 10 (1) ◽  
pp. 401-407
Author(s):  
Yanuar Rohmat Aji Pradana ◽  
Aldi Ferara ◽  
Aminnudin Aminnudin ◽  
Wahono Wahono ◽  
Jason Shian-Ching Jang
Keyword(s):  
Surface Roughness ◽  
Metallic Glasses ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Recast Layer ◽  
Surface Evaporation ◽  
Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

Sign in / Sign up

Export Citation Format

Share Document