Optimization of EDM process parameters: A Review (original) (raw)
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International journal of trend in scientific research and development, 2018
The electrical and non-electrical parameters of EDM influence the performance of EDM. EDM is one of the widely used non-traditional machining process used for machine the hard materials which are difficult to machine by the conventional machining processes. In the past few decades EDM gains popularity because of its wide range of applications in the die-making, aerospace industry and other manufacturing sectors. It is also an alternative method of batch production when the conventional machining processes fail to machine a material. The development in the new hybrid techniques and new tool materials makes some new research scopes in the EDM. Lot of research has been done in EDM optimization, monitoring and its application area but still there are many research gaps which need further study. The aim of this paper to identify the effect of electrical and non-electrical parameters on the performance measures of EDM.
Manufacturing Review
Electro discharge machining (EDM) is a popular unconventional machining process widely employed in die-making industries. Careful selection of process parameters such as pulse current, voltage, on and off time, etc. is essential for machining of hard and conductive materials using EDM. Previous researchers working in the area of EDM have extensively analyzed the machining performance through experimental study, modeling, and simulation and also by theoretical analysis. This article discusses the significant summary of the work performed by earlier researchers through a detailed literature survey. Relevant literature on EDM and impact of process parameters on performance measures such as surface quality, tool wear rate and material removal rate are reviewed. The challenge and limitation of EDM process are also highlighted in this article. It is observed that optimization of process parameters is essentially required for effective and economical machining. So, this article addresses t...
In Present Scenario, Productivity and quality are two important aspects that have become great concerns in today's competitive global market. Every production/manufacturing unit mainly focuses on these areas in relation to the process, as well as the product developed. The electrical discharge machining (EDM) process, even now it is an experience process, wherein the selected parameters are still often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. Material Removal Rate (MRR) during the process has been considered as a productivity estimate with the aim to maximize it, with an intention of minimizing surface roughness taken as most important output parameter. These two opposites in nature requirements have been simultaneously satisfied by selecting an optimal process environment (optimal parameter setting). Objective function is obtained by Regression Analysis and Analysis of Variance. Then objective function is optimiz...
Electrical Discharge Machining (EDM) is a non conventional machining method which can be used to machine electrically conductive work pieces irrespective of their shape, hardness and toughness. High cost of non conventional machine tools, compared to conventional machining, has forced us to operate these machines as efficiently as possible in order to reduce production cost and to obtain the required reimbursement. To achieve this task, machining parameters such as pulse on time, pulse off time, discharge current, gap voltage, flushing pressure, electrode material, etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Electrode/Tool Wear Rate (EWR/TWR), dimensional accuracy, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of EDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper reviews research on improvement and optimization of various performance measures of spark erosion EDM and finally lists down certain areas that can be taken up for further research in the field of improvement and optimization for EDM process.
Optimization of Process Parameters in Electric Discharge Machining Process
Electro Discharge Machining (EDM) is an extremely prominent machining process among newly developed non-traditional machining techniques for “difficult to machine” conducting materials such as heat treated tool steels, composites, super alloys, ceramics, hastelloys, nitralloy, nemonic alloys, carbides, heat resistant steels etc. In EDM, the material removal of the electrode is achieved through high frequency sparks between the tool and the work-piece immersed into the dielectric. The Material Removal Rate (MRR) is the important performance attributes of EDM process. The machining parameters that achieve the highest MRR strongly depend on the size of the machining surface i.e. the engaged electrode and work-piece surface. With upcoming worldwide applications of Titanium grade-2, machining has become an important issue which needs to be investigated in detail. A well-designed experimental were conducted with L18 Orthogonal Array (OA) based on the design of experiment (DOE) with input factors like Peak Current (Ip), Pulse Time On (Ton), Duty Cycle (TAU) and Voltage Gap (V) was considered for investigation. The effect of the machining parameters on the responses such as MRR was investigated. In this research work, Regression analysis was used to find out the optimal levels of the parameters. Keywords: Electric Discharge Machining (EDM), Titanium grade-2, Design of Experiment (DOE), Regression Analysis, Material Removal Rate.
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.
A Review on Optimization of MachiningParameters in EDM
International Journal of Innovative Research in Science, Engineering and Technology, 2015
Electro Discharge Machining or EDM is a machining method primarily used for hard metals or those that would be impossible to machine with traditional techniques. So, Electro Discharge machining (EDM) is one of the important non-traditional machining processes which is used for machining difficult to machine materials like composites and inter-metallic materials. EDM spark erosion is the same as having an electrical short that burns a small hole in a piece of metal it contacts. In the EDM process both the work piece material and the electrode material must be conductors of electricity. Intricate profiles used in prosthetics, bio-medical applications can be done in EDM. Also Electro Discharge Machining (EDM) find a wide range of applications for production of complicated shapes, micro holes with high accuracy in various electrically conductive materials and high- strength temperature-resistant alloys. This paper reviews the various notable works in the field of EDM. And also gives fut...
Optimization of Electrical Discharge Machining Process Parameters Using Desirability Approach
Applied Mechanics and Materials, 2012
Inconel 718 is a high nickel content super alloy having high strength at elevated temperatures and resistance to oxidation and corrosion. EDM process has many advantages over traditional manufacturing process during the machining of inconel 718. In this study experiments were conducted based on the L16 orthogonal array on inconel 718 material using tungsten-carbide (W-C) electrode tool material with kerosene as a dielectric fluid to determine the optimum EDM parameters along with circle(C), square(S), rectangle(R) and triangle (T) tool geometry which contribute to material removal rate (MRR), tool wear rate (TWR) &surface roughness (SR) in machining of inconel 718. Data were optimized using Desirability approach technique. Experimental results show that the current and pulse on time are most influencing parameters that are directly proportional to MRR and inversely proportional to TWR, SR. The rectangle tool geometry gave better results compared to other geometry
International Journal of Advanced Manufacturing Technology, 2006
Electrical discharge machining (EDM) is a non-traditional production method that has been widely used in the production of dies throughout the world in recent years. The most important performance measure in EDM is the surface roughness; among other measures material removal and tool wear rates could be listed. In this study, experiments were performed to determine parameters effecting surface roughness. The data obtained for performance measures have been analyzed using the design of experiments methods. A considerably profound equation is obtained for the surface roughness using power, pulse time, and spark time parameters. The results are discussed.
A REVIEW BASED PAPER ON INVESTIGATION OF PROCESS PARAMETERS AND OPTIMIZATION IN EDM
Among the thermal mode of machining, electrical discharge machining (spark erosion machining) is mainly a method for the manufacturing of a multitude[1] of ever changing geometries very often produced as unit job or in small batches.The basic concept of Electrcal Discharge Machining (EDM) process is creating out of metals affected by the sudden stoppage of the electron beam[3] by the solid metal surfaces of the anode.The portion of the anode facing the direct electrical pulse reaches the boiling point.Even in case of medium long pulse the rate of temperature increases in tens of millions of degree per second which means dealing with an explosion process.In the present work, a combined optimization approach is used for the estimation of maximum metal removal rate(MRR) [5]and minimum tool wear rate(TWR), surface roughness(SR) and overcut(OC) of produced in electrical discharge machining. The important input parameters current (I), pulse on time (Ton), pulse off time (Toff) and voltage (V) are considered.