scholarly journals Effect of deep cryogenic treatment on copper electrode for non-traditional electric discharge machining (EDM)

2019 ◽  
Vol 10 (2) ◽  
pp. 413-427
Author(s):  
Gurdev Singh Grewal ◽  
Dhiraj Parkash Dhiman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Copper Electrode ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Electrode Rotation ◽  
Input Parameters

Abstract. In the last few decades, non-traditional machining made the machining process easier than the traditional machining method. Electric discharge machining (EDM) is one of the most prominent methods of non-traditional machining processes. By the use of EDM, a complex profile and high hardness materials can be easily machined, which cannot easily be machined by the traditional machining method. EDM is widely used by the industries. This paper investigates an experiment with the cryogenically treated copper electrode and an ordinary copper electrode with various input parameters like the electrode rotation, gap voltage and discharge current for an EN24 (a high-strength and wear-resistant steel) material. An experiment was performed with electric discharge machining. Designs of an experiment are carried out using the Taguchi approach. An orthogonal L16 array prepared and used the different combination of the three input parameters (current, electrode rotation and gap voltage) to find an optimum value of the factors. The output factors are the overcut (OC), the tool wear rate (TWR) and surface roughness (Ra). The optimal level and importance levels of each of these parameters are obtained statically using an analysis-of-variance (ANOVA) table through the analysis of the S∕N ratio. The study also compares the theoretical and experimental values of the overcut, tool wear rate and surface roughness for traditional and non-traditional EDM. The following research finds optimal or dominating factors (current and rotational speed) for the TWR and Ra in both traditional and non-traditional electric discharge machining; moreover there was a reduction of approximately 9 % in overcut, 13.25 % in the tool wear rate and 15.75 % in surface roughness for the deep cryogenic and non-traditional machining process.

scholarly journals Optimization of Machining Variables in Electric Discharge Machining Using Stainless Steel 317 in Full Factorial Method

2020 ◽  
Vol 22 (1) ◽  
pp. 105-118 ◽  
Author(s):  
S. Nandhakumar ◽  
S. Sathish Kumar ◽  
K. Sakthivelu
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Machining Time ◽  
Input Variables

AbstractElectric Discharge Machining (EDM) is a non-conventional machining process and has a larger extent of application in manufacturing industry due to its accuracy. EDM simply uses electrical spark between the tool and workpiece in presence of dielectric medium to erode the workpiece in controlled manner. Improving the material removal rate and decreasing the tool wear rate (TWR), achieving higher surface finish, reducing machining time and enhancing dimensional accuracy are the major areas of focus in electrical discharge machining (EDM) process of SS 317 grade steel. In this research work effort to reduce the tool wear rate is concentrated by comparing the machining performance of two distinct electrodes namely copper and brass. Each electrode has their unique machining capabilities and the experimental results were compared in-terms of tool wear rate (TWR), Metal Removal Rate (MRR) and Machining Time (TM). Input variables were optimized based on the experimental output responses to achieve optimal level of input variables.

Process Optimization of Electric Discharge Machining Using Response Surface Methodology

2015 ◽  
Vol 813-814 ◽  
pp. 393-397
Author(s):  
Rajinder Kumar ◽  
Neel Kanth Grover ◽  
Amandeep Singh
Keyword(s):  
Response Surface Methodology ◽  
Wear Rate ◽  
Tool Wear ◽  
Response Surface ◽  
Electric Discharge ◽  
Material Removal ◽  
Machining Process ◽  
Work Piece ◽  
Tool Wear Rate ◽  
Electric Discharge Machining

Electric Discharge Machining (EDM) is one of the most commonly used non-traditional machining processes. Complex geometries can be easily manufactured using EDM. Material removal is achieved by producing continuous spark occurring between well shaped tool electrode and work piece. EDM does not involve direct contact of tool and work piece. Machining process involves a number of input variables like, current, voltage, pulse on/off which in turn affect the machining efficiency of EDM. These process parameters must be optimized to attain high material removal rate and low tool wear rate. The present paper presents theoptimization of tool wear rate of copper and brass electrode on machining of EN-47 using Response Surface Methodology (RSM).

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

scholarly journals Machinability Of Shape Memory Alloy Using Electro Spark Erosion Process 

2021 ◽  
Author(s):  
Adam Khan M ◽  
Winowlin Jappes J T ◽  
Samuel Ratna Kumar P S ◽  
Mashinini P M
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Shape Memory ◽  
Applied Voltage ◽  
Material Removal ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Pulse On Time ◽  
The Impact

Abstract In this research work, the nickel – titanium based shape memory alloys are machined using electro spark machining process. The influence of the input process for electro spark production is studied in detail. From the analysis, the tool wear rate (TWR), surface roughness, and material removal rate (MRR) are investigated. The intensity of the electro spark produced at minimum pulse on-time 10 µs and maximum applied voltage (60 V). Variation in MRR is wide for a minimum pulse on time with low applied voltage. The surface roughness of the machined surface is also directly influenced by the in – efficient spark produced. The copper electrode with increase pulse duration the alloy behaves like a strong conductor to transmit electrical energy between the electrode and work material. The contribution of pulse on-time is maximum for material removal and tool wear rate. However, the surface finish depends on the applied voltage of the process designed. The impact on machined surfaces, micro-cracks, electro-discharge carter's, and recast material due to electrical discharge were assessed using a scanning electron microscope and energy-dispersive X-ray spectroscopy (EDX) analysis. The experimental value shows that material removal depends on the pulse on process timings and applied voltage. Thus, by using mathematical analysis the influence of (electric discharge machining) EDM process parameters was evaluated.

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