Optimization the Effect of Electrode Material Change on EDM Process Performance Using Taguchi Method (original) (raw)
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Optimization is a process or a technique to make something perfect or effective as much as possible. Optimization is one of the best methodology used in manufacturing and production sectors to attain the optimal manufacturing conditions at lower cost with the optimal results. Electric discharge machining is the non-traditional machining process. Basically, EDM is used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the work piece and the electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and work piece. Aim of this paper was to investigate the optimal set of process parameters such as Voltage, Current and Pulse on time in the electric discharge machining to identify the variations in the three characteristics such as Material removal rate (MRR), Tool wear rate (TWR), and Surface roughness (Ra) on the work piece Mild Steel IS 2026 and the electrode is Copper. Machining process is done to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. Taguchi method and ANOVA technique is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR,TWR and surface roughness. KEYWORDS: Electric discharge machining, Mild Steel IS 2026 work-piece, copper electrode, Current, Voltage, Pulse on time, Taguchi L9 orthogonal array, Miinitab-17, ANOVA, S/N ratio, Surface Roughness (Ra), Material Removal Rate(MRR), Tool Wear Rate(TWR). .
Proceedings of the National Conference on Trends and Advances in Mechanical Engineering,, 2017
Optimization is a process or a technique to make something perfect or effective as much as possible. Optimization is one of the best methodology used in manufacturing and production sectors to attain the optimal manufacturing conditions at lower cost with the optimal results. Electric discharge machining is the non-traditional machining process. Basically, EDM is used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the work piece and the electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and work piece. Aim of this paper was to investigate the optimal set of process parameters such as Voltage, Current and Pulse on time in the electric discharge machining to identify the variations in the three characteristics such as Material removal rate (MRR), Tool wear rate (TWR), and Surface roughness (Ra) on the work piece Mild Steel IS 2026 and the electrode is Copper. Machining process is done to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. Taguchi method and ANOVA technique is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR,TWR and surface roughness.
Optimization of Process Parameters in Electro- Discharge Machining using Taguchi Method
Electric discharge machining is the essential non-traditional machining process. Basically the EDM is mainly used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the workpiece and electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and workpiece. With the help of optimization techniques we can attain the best manufacturing environment, which is an essential need for industries to improve the manufacturing qualities of products at the lower cost. This research paper aims to investigate the optimal set of process parameters such as pulse on time, voltage, current in the Electric discharge machining process to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. The experiment is done on the Mild steel AISI18 work piece and the electrode taken is of copper. Taguchi method is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR, TWR and surface roughness. At higher value of Voltage, lower value of current & lower value of pulse on time we get the best optimal values of MRR, Ra & TWR. Keywords: Electric discharge machining, AISI18 steel work-piece, copper electrode, Current, Voltage, Pulse on time, Taguchi L9 orthogonal array, Miinitab-17, S/N ratio, Surface Roughness (Ra), Material Removal Rate(MRR), Tool Wear Rate(TWR) ________________________________________________________________________________________________________
Literature Review on Electrical Discharge Machining (EDM
International Journal for Scientific Research and Development, 2018
By means of the improvement and growths in new machineries, low weight- high strength, high hardness and temperature resistant materials have been advanced for distinctive applications which include aerospace, medical, automobile and more. In the machining of hard and metal matrix composite materials, outdated manufacturing processes are being more and more changed by more non-traditional machining processes which include Electrical Discharge Machining (EDM). The work piece material designated in this experiment is Inconel 925 taking into interpretation its wide usage in industrial applications. In today’s world stainless steel provides to nearly half of the world’s production and consumption for industrial determinations. In this experiment the input variable factors are voltage, current and pulse on time. As we know that Taguchi method is functional to produce an L9 orthogonal array of input variables by means of the Design of Experiments (DOE). So, Taguchi method is used to analysis the output data. The consequence of the compliant parameters stated overhead upon machining characteristics such as Material Removal Rate (MRR) and Tool Wear Rate (TWR) is considered and examined. In this we are focused on to analysis minimum TWR and maximum MRR based on control factors and response parameters.
Indian Journal of Science and Technology, 2016
Objectives: To find the important parameters that affects the performance output (i.e.) to boost the Material Removal Rate (MRR) of the workpiece. Methods: Electro-Discharge Machining (EDM) is a thermal based machining process which is used to remove 'hard to cut materials' with complex shapes. The principle with the EDM or spark eroding machining is that the unwanted materials are removed with the repeated current discharges between cathode and the anode, separated by a dielectric fluid and is subjected to an electric voltage. Findings: This paper investigates in optimizing the process variables of EDM by employing a traditional technique. The parameters chosen for optimization are pulse on time, pulse off time followed by the current and L 9 Orthogonal Array (OA) has been selected to examine the impact of the process variables on the performance i.e. on the material removal rate. The experimental trials have been done on AISI D2 die steel with positive polarity and brass has been chosen as an electrode material. Applications: Mainly, the EDM are employed to machine difficult to cut materials like nickel base super alloys, titanium etc.
Electric Discharge Machining (EDM) is one of the most efficient employed non-traditional machining processes for cutting hard-to-cut materials. .Modern ED machinery is capable of machining geometrically complex or hard material components. Heat treated tool steel, composites, super alloys, ceramics, etc. In the present work, an experimental investigation has been carried out to study the effect of pulsed current on Material Removal Rate, Electrode Wear Rate and surface roughness in M2 tool steel. The present material used for the work were Harden up to 62 HRC and then machined with electrode materials of copper and Tungsten copper (75:25 grade) with square section of 10×10 mm and 35 mm in length. Then in second part of present work optimization of output parameters such
Electric Discharge Machining (EDM) is one of the most efficient employed non-traditional machining processes for cutting hard-to-cut materials. .Modern ED machinery is capable of machining geometrically complex or hard material components. Heat treated tool steel, composites, super alloys, ceramics, etc. In the present work, an experimental investigation has been carried out to study the effect of pulsed current on Material Removal Rate, Electrode Wear Rate and surface roughness in M2 tool steel. The present material used for the work were Harden up to 62 HRC and then machined with electrode materials of copper and Tungsten copper (75:25 grade) with square section of 10×10 mm and 35 mm in length. Then in second part of present work optimization of output parameters such as Material Removal Rate (MRR) and Surface Roughness during electric discharge machining of M2 tool steel using Grey-Taguchi analysis with L9 Orthogonal Array has been done. The Result shows that Copper can be replacing by Tungsten Copper electrode. The results reveal that High Material Removal Rate and Depth have been achieved with Tungsten copper electrode at process parameters Discharge current 15A, Pulse on time 45µs, pulse off time 9µs and Spark gap of 20µm and for Surface Roughness at Discharge current 5A, Pulse on time 15µs, pulse off time 6µs and Spark gap of 20µm using Taguchi approach, whereas using Grey Relational Analysis approach shows best result at Discharge current 15A, Pulse on time 15µs, pulse off time 9µs and Spark gap of 20µm.
Mindanao Journal of Science and Technology
Electrical discharge machining (EDM) is one of the most crucial non-traditional machining methods used in molds and dies manufacturing, and conductive materials machining, which are difficult to machine by traditional methods. The EDM performance is affected by several machining parameters with different contribution percentages. In this study, the experimental investigations were conducted on DIN 2767 tool steel using CuCrZr, Cu and CuCo1Ni1Be (CNB) electrodes. The most influential process parameters were focused on to improve the EDM performance. The value of the process parameters and their levels were discharge current (6, 12 and 25 A), pulse-on time (50, 200 and 800 μs) and pulse-off time (50, 200 and 800 μs). Optimal levels of machining process parameters were obtained by employing the Taguchi L27 orthogonal arrays. The experimental results showed that the optimal combination of the machining parameters for maximum material removal rate was A3B2C1 using a CNB electrode. For mi...
OPTIMIZATION OF PROCESS PARAMETERS IN ELECTRICAL DISCHARGE MACHINING PROCESS BY USING TAGUCHI METHOD
The objective of this research study is to investigate the optimal process parameters of Electric Discharge Machining on RENE80 nickel super alloy material with aluminum as a tool electrode. The effect of various process parameters on machining performance is investigated in this study. The input parameters considered are current, pulse on time and pulse off time are used for experimental work and their effect on Material Removal Rate, Tool Wear Rate and Surface Roughness. The Taguchi method is used to formulate the experimental layout, ANOVA method is used to analysis the effect of input process parameters on the machining characteristics and find the optimal process parameters of Electric Discharge Machining. The results of the present work reveal that proper selection of input parameters will play a significant role in Electric Discharge Machining.
Al-Qadisiyah Journal for Engineering Sciences
EDM (Electrical Discharge Machining) is a common non-traditional machining technique for manufacture geometry parts made of intricate or extremely rigid metals that are challenging to manufacture using conventional manufacturing techniques. Electrical discharge machining by utilizing electrical discharge erosion, classify the meaning of material removal (MR). This paper's main objective is to discuss the ideal EDM parameters in order to use high-speed steel as workpiece AISI M2 and with using brass & copper as electrodes. Pulse on-time are (100, 150, and 200 µs), Current (10, 24 and 42 A) and Pulse off-time (4, 12 and 25 µs) are the input parameters effect on the material removal rate (MRR) used in the experimental work. The present study's findings shown that the highest MRR with using copper & brass as electrodes with pulse on-time 200 µs, pulse off-time 12 µs and current 42 A, at (0.31284 g/min and 0.18769) respectively, and the lowest average value of the removed materia...