Analysis of the influence of input parameters of EDM on material removal rate and surface roughness for machining stainless steel 304 (original) (raw)
Related papers
2019
This paper depicts the experimental study of the input parameters of EDM current, pulse on time and pulse off time on output parameters material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR). The workpiece materials selected was C100. The coppertungsten used as tool electrode. After the experiments, MRR, EWR, Roundness, and Ra of the machined surfaces need to be measured in order to evaluate the performance of the EDM process. In order to obtain high MRR, the higher peak current in a range of 0.2A to 128A and pulse duration in a range of 0.5μs to 20μs were used. Experimental results have shown that machining at a highest peak current used of 128A and the highes pulse duration of 20μs used for the experiment yields the highest material removal rate (MRR) with value 57.2mm/min, whereas machining at a peak current of 128A and pulse duration of 20μs yields the lowest electrode wear rate (EWR) with value -4.29mm/min. The lowest surface roughness (Ra) is 0.8 μm achie...
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 In the machining of hard and metal matrix composite materials, outdated manufacturing processes are being more and more changed by more non-traditional machining processes which include Electrical Discharge Machining (EDM).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.
ARTICLE INFO ABSTRACT Generally the non-convectional machining processes use thermal source of energy for the material removal. Among them Electrical discharge machining (EDM) or spark erosion machining is most important one. The important process parameters in this technique are discharge pulse on time, discharge pulse off time current and gap voltage. The values of these parameters significantly affect such machining outputs as material removal rate. In the present research, an axisymmetric thermo-physical finite element model for the simulation of single sparks machining during electrical discharge machining (EDM) process is exhibited and the model has been solved by using ANSYS 11.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties has been used to investigate the temperature distribution on the surface. Material removal rate was calculated for multi-discharge machining by taking into considerations...
2014
Abstract: Electrical Discharge Machining (EDM) is now a well-established machining option in many industries. EN-9 is an important tool mainly because of its high hardness, strength, wear resistance and high melting point. Normally, EDM is capable of machining geometrically complex or hard material component, that are precise and difficult to machine. The objective of this research is to study the performance of different electrode Materials on EN-9 workpiece with EDM process. Approach: The electrode materials were graphite, copper and Brass. The important parameters were peak current, pulse on time, pulse off. A workpiece material was EN-9. Results: The results show that the Graphite electrode gives higher MRR than other two Electrodes. Brass electrode gives better surface finishing among three electrodes. Powder electrode gives the better MRR and high SR more than solid electrode.
Determination of Material Removal Rate in Electro Discharge Machining through Copper Electrode
International Journal for Research in Applied Science & Engineering Technology, 2021
In the present manufacturing area, Electro discharge machining is one of the most emerging area for production of various components. Electro-discharge machining (EDM) is a thermoelectric process which utilizes the heat energy generated by spark to remove the material from the surface of work-piece. In the EDM process material removal takes place from both tool material and work-piece. The material removal rate depends upon the work-piece material, tool material and machining variables. Materials having low melting point having high material removal rate and hence lower surface finish. It is found that with increase in pulse current and constant pulse-on-time material removal rates increases but it affects the surface finish of material. EDM efficiency can be increased by supplying the oxygen gas between the spark gap and stack removal rate can be increased by increasing the volume of discharge crater and regular occurrence of discharges. The only limitation in the EDM is that the work-piece and the tool material both should be electrically conductive. The electrical energy converted into the thermal energy by series of the electric discharge that occurred between the work-piece and tool which are immersed into the dielectric fluid. The plasma channel is generated by thermal energy between anode and cathode. The plasma channel is generated at a temperature range of 8000-1200°C. Sometimes it is nearly about 20,000°C which is too high and can machine any material. The location of electric spark which is generated by heat energy is determined by the narrowest gap between the tool and work-piece. Duration for each spark is very short. The frequency for each spark is high as thousands sparks per second. However, spark radius is very small and the temperature in the spark zone is very high. This temperature of spark is capable for partially vaporize and melting the material from both the work-piece and tool material. The volume of material removal per discharge from the work-piece depends upon the specific applications and it is ranging from 10-6-10-4 mm 3. The material removed from the surface of work-piece is in the form of craters which is all overspread on the work-piece. Craters sizes are highly influenced by the value of current. Machining of Titanium alloy is carried out using EDM process. This paper presents evaluation and study of Material removal rate of titanium alloy using copper electrode in electro discharge machining 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.
Study of Material Removal Rate and Surface Roughness on D2 Steel in Electro-discharge Machining
2016
ARTICLE INFO In the present study, D2 steel is machined in die sink electro-discharge machine with electrolytic copper and bronze tool to analyze the machining characteristic. The process parameters such as pulse on time (T on), pulse off time (T of f) and peak current (I p) are taken as the input variables whereas metal removal rate (MRR) and surface roughness (SR) are chosen response variables. The experimentation was conducted using Taguchi's L9 orthog onal array with different combination of process parameters. The signal to noise (S/N) ratio of each experimental data has been found to correlate the input variables with res ponse variables. Also Analysis of Variance (ANOVA) technique is used to check the significance of the model and confirmation test is conducted to compare the experimental data with the predicted data to identify the effectiveness of the proposed method. Furthermore, from the ANOVA result, it is found that peak current is the most significant parameter amo...
Electrical discharge machining is a nonconventional machining process which enables machining of complex and intricate shapes, hard materials that are precise and difficult to machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The process involves spark erosion in the presence of dielectric fluid. In this work SCM 420low alloy steel is the material used for the machining purpose with electrolyte copper as tool. This work investigates effect of process parameters peak current (I P), Pulse on time (T on) and gap voltage (Vg) on Material removal rate (MRR) and surface roughness (R a). Response surface methodology is used for experimental design. The suggested model can be used in the different manufacturing firms by selecting right combination of process parameters to achieve optimal values of output responses.
Study on Electrical Discharge Machining and Effect of its Parameters
The Electrical Discharge Machining (EDM) is one of the most common and most accepted non-traditional machining processes used in tooling industries. EDM is an important manufacturing method developed in 1940's. The forming tools to produce plastic molding die casting, forging dies etc. It is an electro-thermal process and is based on eroding effect of an electrical spark on both electrode and work piece. It is a thermal erosion process where metal removal takes place by series of recurring electrical discharges between cutting tool acting as an electrode and a conductive work piece in the presence of a dielectric fluid. The dielectric fluid will be flooded in a small gap of about 0.01mm to 0.5mm. This discharge occurs in voltage gap between the electrode and work piece. Currently, non-traditional process possess virtually unlimited capabilities except for volumetric material removal rates, for which great advances here been made in past few years to increase the cost effectivene...
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/an-experimental-investigation-on-machining-parameters-of-electrical-discharge-machining-of-ohns-steel https://www.ijert.org/research/an-experimental-investigation-on-machining-parameters-of-electrical-discharge-machining-of-ohns-steel-IJERTV2IS121070.pdf Presently manufacturing industries are facing various challenges from these advanced materials viz. super alloys, ceramics, and composites, whose mechanical properties are hard and difficult to machine. It requires high precision, surface quality which increases machining cost. To meet these technological challenges, non-conventional machining processes are being employed to achieve higher metal removal rate, better surface finish and greater dimensional accuracy, with less tool wear. Electric Discharge Machining (EDM) is a non-conventional process and has a wide applications in automotive, defense, aerospace and micro systems industries plays an excellent role in the development of cost effective products with more reliable quality assurance. Here we report and analyse the various parameters in Electrical Discharge Machining. Experimental results are discussed on electric discharge machining of OHNS (Oil Hardening non Shrinking Tool Steel) Die material in Copper and Aluminium electrode. Statistical analysis is presented to identify the effect of process input factors (viz. current, voltage) on the output factors viz. Material Removal Rate (MRR), Electrode Wear Rate (EWR). Keyword-Electrical discharge machining (EDM), Material removal rate (MRR), Tool wear rate (TWR), Oil Hardening non Shrinking Tool Steel (OHNS),