Parametric Optimization of EN-31 Steel in Wire Cut Electro Discharge Machining by Taguchi Technique

Amongst the various methods of machining, Electro Discharge Machining is the convenient alternatives for the industries due to non-contact of work piece and tool. In the study of various EDM processes the main target is to achieve the better finish of surface, high material removal rate and good dimensional accuracy by regulating the different input parameters. There are various applications of EDM such as aerospace parts, medical equipments, dies and moulds, nuclear and automobile industry. In this experimental study, a trial has made to look the impact of input factors like pulse-on, pulse-off, peak current, tension of wire on rate of material removal, gap current and time for machining. Taguchi (L9 OA) and Analysis of Variance technique were used to optimize the outcomes for wire cut EDM of EN-31 tool steel. The outcomes revealed that Ton and Toff are the leading cogent factor for material removal rate and gap current respectively.

Study the effect of process parameters on Electric Discharge Machining: Literature Review

Electrical discharge machining (EDM) is one of the earliest non-conventional method of manufacturing processes. This process based on thermoelectric energy between work piece and electrodeand they must have electrical conductivity to generate the spark. A spark generated between work piece and electrode, and removes the material from work piece through melting and vaporizing. EDM produced various types of products such as dies and moulds. EDM is used to manufacture the parts of aerospace, automotive industry and surgical components. The effect of the machining parameters on surface roughness, metal removal rateand tool wear rate are studied.

Forecast of Limit Cutting Depth for Hardened Mould Steel Milling

This paper focus on automobile panel dies and moulds, studying the sliding friction phenomenon between tools and workpiece caused by inadequate margin adopted during finishing. Based on this, the forecasting model of the limit milling depth is built with the consideration of tool deformation. Further on, the model built is tested by milling experiments with different radii of curvature, and providing the evidence for adoption and optimization of margin of steel finishing.

Influence of Electrode Cooling on Material Migration among the Electrodes during EDM of Titanium Alloy

Electrical discharge machining (EDM) is widely used in the machining of electrically conductive hard metals for the production of dies and moulds. This paper describes an investigation of the effect of electrode cooling on the amount of elements migration from the electrode to the workpiece surface and from the workpiece to the electrode surface. In the present study EDM has been performed with electrodes cooled by liquid nitrogen as well as with electrodes without cooling. Current, pulse-on time, pulse-off time and voltage were taken as the variables during conducting the experiments. The analysis on material migration during EDM was carried out by SEM and EDX. It was observed that EDM with liquid nitrogen reduces material migration and minimizes the surface contamination of both the electrodes.

Current Research Trends on Dry, Near-Dry and Powder Mixed Electrical Discharge Machining

Electrical discharge machining (EDM) technique has been widely used in modern metal working industry for producing complex cavities in dies and moulds, which are otherwise difficult to create by conventional machining. The process has the advantage of being able to machine hardened tool steels. However, its low machining efficiency and poor surface finish restricted its further applications. To address these problems, one relatively new technique used to improve the efficiency and surface finish is EDM in the presence of powder suspended in the dielectric fluid. Powder mixed electric discharge machining (PMEDM) is one of the recent innovations for the enhancement of capabilities of EDM process. In PMEDM, the electrically conductive powder is mixed in the dielectric fluid of EDM, which reduces the insulating strength of the dielectric fluid and increases the spark gap between the tool and workpiece. As a result, the process becomes more stable, thereby, improving the material removal rate (MRR) and surface finish. Moreover, the surface develops high resistance to corrosion and abrasion. This paper presents the current research trends on dry, near dry EDM and review on research carried out in the area of PMEDM.