Multiple-Performance Optimization of Wire EDM Parameters for HDS H13 BY Using Taguchi Method

Wire electrical discharge machining is extensively used in machining of conductive materials. The WEDM process has the ability to machine complex shapes and hard electrically conductive metal components precisely. The main goal of wire electrical discharge machine manufacturers and users are to achieve a better stability and high productivity of the process with desired accuracy and minimum surface damage.The main objectives of the present research are to experimentally study the effect of various process parameters like pulse on time, pulse off time, wire feed, and wire tension on the performance measures like material removal rate, surface roughness and wire wear ratio. WEDM is a widely recognized unconventional material cutting process used to manufacture components with complex shapes and profiles of hard materials. In this paper we are presenting the development of WEDEM process using various pre define parameters using Taguchi method. Index Terms: WEDM, doe, orthogonal array, parameters, Taguchi method, H13, HDS, mean of means, SF, MRR, Ra, etc.

Impact of orbiting electrode motion on the accuracy of electrical discharge machining

The present study is designed to study processes occurring during the electrical discharge machining (EDM) of tool steels, the influence of orbiting electrode motion on its accuracy, as well as to justify the application of individual orbiting trajectories and implement these data into production. To that end, a trajectory program was written in machine codes for a Mitsubishi EA-28 die-sinking electrical discharge machine using the CIMCO EDIT software package. Also, a prototype punch and ejector of the blanking die were produced and measured. The standard modes of Mitsubishi EA-28 were used to carry out machining in Blasospark GT 250 dielectric fluid to a roughness of Ra 0.6 in 9 passes. The experiments revealed the influence of electrode geometry on the machining of sharp corners, i.e., the formation of unwanted radii on the workpiece. However, this phenomenon is not observed when the corners are drilled with small diameter holes (0.4–0.6 mm). Depending on the machining process along the inner or outer trajectory, inverse electrode motion is also observed. The production part (punch of the blanking die) was machined using a new orbit adjusted to the geometry of the product. The part was found to be consistent with the requirements and the engineering drawing, thus allowing the assembled die to enter the main production. The results of the performed tests, as well as the study of domestic and foreign experience, were used to develop recommendations on the use of individual orbits in the EDM of tool steels, hard alloys, and other hard-to-machine conductive materials. The method of orbiting motion along a particular trajectory was implemented at Cheboksary Electrical Apparatus Plant (Cheboksary).

Modelling and optimization of energy intensity of an electrical discharge machine

Nowadays, high fabrication productivity and high-quality products are a matter of course. However, it would not be possible without the use of highly sophisticated progressive technologies in the production process. But many of these modern production technologies are characterized by high consumption of energy. Given the current energy prices, this is not an insignificant amount of money. It is also necessary to point out, that in many cases the rule concerning the mutual interconnection of the energy intensity of production technologies with the resulting quality of the machined area applies. These reasons led us to the optimization of energy consumption in the context of the required quality of the machined surface in terms of selected indicators. The paper aims to describe the results of the performed experimental measurements in order to create mathematical models with subsequent optimization of electricity consumption of an electrical discharge machine. Unlike many types of research conducted in the field so far, the results of the solution were based on determining the relationships between the energy intensity of the electrical discharge machine and its controllable outputs in terms of the final roughness of the eroded surface. The performed optimization based on experimentally obtained results was directed so that its results could be applied in real conditions of technical practice.

Effect of Various Process Parameters of EDC on Mild Steel Substrate and their Properties

In the present study, A layer of the modified composite coated surface is made using Copper, molybdenum disulfide, and hexagonal boron nitride. For this process, Electrical discharge machine (EDM) is used but in reverse polarity. Various factors of the machine influenced the thickness of the deposited layer like the amplitude of peak current, duty factor, powder mixing ratio, used etc. For the deposition process, green compacted electrodes which was made after mixing the powder material in mortar for approximately 2.5 hour and post processing in Hot mount press moulding machine. After that the mixture powder was put in the Hot mounting press machine to made green compact electrode with specific parameters. Experiment was performed on EDM and many analysis were carried out to study the morphology of the coated surface. To get the morphology of the coated layer, FESEM images were examined and found the satisfying uniform distribution of deposited layer constituents with material powder mixing ratio of (Cu/HBN/MoS2) at (20/40/40) got with 50% duty factor and 10 Ampere peak current amplitude. Also done XRD, for the evidence of Cu, MoS2 and HBN.

Formation and Optimization of Electrical Discharge Coatings Using Conventional Electrodes

An emerging topic is electrical discharge (ED) coating with its application on complex shapes and cavities to repair components or act as functional coatings. Because it is a variant process of an electric discharge machine (EDM) with the ability to coat on electrically conductive substrates, there is a possibility that next-generation electrical discharge machining components may exploit the attachment phenomenon to enhance recast layer properties. Previously, researchers have obtained ED coating by mixing the powder in a dielectric medium and/or by using powder metallurgy electrodes. In this work, primarily, an insight in the formation of ED coating on-die sinks electrical discharge machine, using conventional electrode materials viz., bronze on titanium alloy (Ti-6Al-4V) is made. The bronze electrode on the titanium substrate obtained a crack-free copper coating of ~20 microns thickness. In order to perform the experiments, three combinations were made using five parameters: current (Amps), ton (µs), Toff (µs), duty cycle (%), and flushing pressure as constant (bar). After obtaining the coating, a combination of input parameters was selected by optimizing the output performance parameters, viz., the electrical discharge deposition rate, coating thickness, micro-cracks, and elemental coating composition. Secondarily, different optimization techniques viz., grey relational analysis, the technique for order of preferences by similarity to ideal solution, −nD angle method and information divergence method were implemented to find out the suitable combination of parameters where the latter two methods were introduced for the first time in this area of EDM optimization. A study was conducted to check whether the latter two methods are optimization techniques or multi-criteria decision-making techniques. The optimization of existing reactor types and the development of new reactors in wastewater treatment through EDC, by which energy could be saved by replacing the conventional techniques.

A review on the effect of using rotary hyflex electrical discharge machining endodontic files on the formation of dentinal microcracks in straight root canals

Endodontic therapy is based on cleaning and shaping the canal system till the apex with total obturation of the canal. However, it is not always straightforward. Endodontics specialists face many complicated cases as sever curved canals, calcified canals and canals with previously initiated therapy which require to deal with. dental professionals pay attention to create new methods or to improve the already developed equipment and procedures to facilitate their work. Rotary endodontics files are in the center of attention. nowadays, recent files with extraordinary properties have been revolutionized. The standard Nickel Titanium rotary endodontic files are not always preferred. It cannot serve well in the aforementioned complex cases due to its larger tapers and unique shape memory property. Moreover, these files have led to several dentinal microcracks formation during canal preparation using the flaring instruments. Microcracks are evaluated through the accurately presented sliced images using Micro-Computer Tomography (micro-CT) done before and after root canal preparation. This has led to the invention of new generations of rotary endodontics files, with unique properties improving its behavior during the instrumentation, including Controlled Memory (CM) files and Electrical discharge Machine (EDM) files, opening the door for a new era in the field of endodontics dentistry. The present study aims to review HyFlex EDM files, including their properties, clinical dental usage, and the role of micro-CT in analyzing dentinal micro cracks formed with HyFlex EDM files.

Effects of Electrical Parameters during Non conventional Machining of Al/Sic Metal Matrix Composites by Electrical Discharge Machine

Particulate Reinforced Al/SiC Metal Matrix Composites (PRALSICMMC) is gradually becoming very important materials in manufacturing industries e.g. aerospace, automotive, and automobile industries due to their superior properties such as lightweight, low density, high strength to weight ratio, high hardness, high temperature, and thermal shock resistance, superior wear and corrosive resistance, high specific modulus, high fatigue strength, etc. In this study aluminum (Al- 6063)/SiC Silicon carbide reinforced particles metal-matrix composites (MMCs) are fabricated by melt-stirring technique. The MMCs bars and circular plates are prepared with varying the reinforced particles of SiC by weight fraction ranging from 5%, 10%, 15%, and 20%. The average reinforced particles sizes of SiC are 220 mesh, 300 mesh, and 400 mesh respectively. The stirring process is carried out at 150 revs/min rotating speed by graphite impeller for 15 min. A series of machining tests are performed on EDM. Copper electrodes are used as tools (cathode), Prepared specimens of Al/SiC MMCs are used as workpiece (anode) and kerosene is used as the dielectric fluid. The Performance parameters measured during experimentation were Tool Wear Rate (g/min), Metal Removal Rate (g/min), Over Cut on diameter (mm), and Average Surface Roughness Ra (μm) for each experiment by varying Pulse Peak Current IP (2 Amp, 6 Amp, 10 Amp,14 Amp) and gap voltage Vg ( 25 Volts, 30 Volts, 35 Volts, and 40 Volts). The investigations of results are done graphically.