Effects of Input Parameters on Electrode Wear Rate when EDM Cylindrical Shaped Parts

In electrical discharge machining (EDM) process, the selection of suitable EDM factors plays an important role since this can achieve the growing need for quality, minimizing manufacturing cost and time, and reducing electrode wear rate. This paper presents the effect of input factors on electrode wear rate (EWR) when machining cylindrical shaped parts made from 90CrSi steel and an optimization of these parameters. The input EDM parameters include the pulse on time, the pulse off time, the current, and the spark gap voltage. The Taguchi method with L27 was used for designing the experiment to gather data. Based on statistical analysis of experiment data, the impact of the input factors on the EWR was investigated. Moreover, the optimal input parameters were found by evaluating the S/N ratio in order to minimizing the EWR. This brings the significance in minimum surface roughness and high accuracy of machining elements.

Investigation the Electrode Wear Rate and Metal Removal Rate in EDM Process using Taguchi and ANOVA Method

The experimental work of this paper leads to electrical discharge machining (EDM). A system for machining in this process has been developed. Many parameters are studied such as current, pulse on-time, pulse off time of the machine. The main aim of this work is to calculate the metal removal rate (MRR) and electrode wear rate (EWR) using copper, electrodes when machining tool steel H13 specimens of a thickness (4mm). Different current rates are used ranging from (30, 42, and 54) Amp, pulse on-time ranging from (75, 100, and 125) and pulse off time ranging from (25, 50, and 75) found that high current gives large electrode wear and metal removal rate and. The experiment design was by Taguchi Method. From an analysis of variance (ANOVA) the more active influence of input factors on the outputs is currently for metal removal rate (MRR) (58%) and electrode wear rate (EWR) (57).

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

The present investigation addresses the machining outcome of electric discharge machining using a rapid manufactured complex shape copper electrode. Developed rapid manufacturing technique using an amalgamation of polymer 3D printing and pressureless sintering of loose powder as rapid tooling has been used to fabricate copper electrode from the computer-aided design model of the desired shape. The fabricated electrode was used for the electric discharge machining of the D-2 steel workpiece. Central composite design was employed to study the electric discharge machining parameters (pulse duration, duty cycle and peak current) effect on the electric discharge machining characteristics such as material removal rate, electrode wear rate and cavity dimensional deviation as overcut from electrode computer-aided design model. Analysis of variance was executed to attain significant parameters along with interactions. Peak current was found to be the utmost dominating parameter for three responses. The high percentage of carbon was observed on the electrode surface after electric discharge machining at the high level of pulse duration and resulted in low electrode wear rate. The high percentage of dimensional deviation was noticed at the maximum duty cycle and maximum peak current by the substantial interactions. Genetic algorithm-based multi-objective optimization was employed for the electric discharge machining parameters optimization to maximize material removal rate, minimize electrode wear rate and dimensional deviation. The multi-feature complex copper electrode was fabricated and used for electric discharge machining as the case study to check the efficacy of the optimized process. It was witnessed that the process was competent to fabricate complex shape cavity as per the desired computer-aided design model shape with efficient material removal rate and electrode wear rate.