dc meet

1. EXPERIMENTAL INVESTIGATION ON ELECTRICAL
DISCHARGE MACHINING WITH DIFFERENT TYPES
OF TOOL ELECTRODE ON AISI H13 TOOL STEEL
First Doctoral Committee Meeting
Presented By
R.GOPAL,
Ph.D., PT/002
Guided By
Dr.P.Senthil,
Professor
DEPARTMENT OF MECHANICAL ENGINEERING
Karpagam University
Coimbatore - 641021

2. Doctoral Committee Members:
Dr.P.Senthil,
Professor,
Department of Mechanical Engineering,
Karpagam University,
Coimbatore.
Dr.V.Muthukumaran,
Professor,
Department of Mechanical Engineering,
Kumaraguru College of Technology,
Coimbatore.
Dr.P.Shanmughasundaram,
Professor,
Department of Mechanical Engineering,
Karpagam University,
Coimbatore.

3. Introduction
Electrical Discharge Machining Process:
EDM process is a emerging unconventional machining process in which
metal is removed by the series of high intense spark discharge at the gap
between work piece metal and tool electrode. This process found useful in
machining the complex shape on hardest conductive materials.

4. Applications
Mold making tool and die industries,
Aerospace,
Automobile and
Electronic industries
Introduction Contd…

5. Measure of performance level
Based on:
Output Parameters
- Metal Removal Rate (MRR)
- Surface Roughness (SR)
- Tool Wear Rate (TWR)
These parameters responds for the following
input parameters:
- Voltage
- Current
-Spark Gap
- Dielectric fluid and its circulating pressure
- Properties and design of tool electrode
- Properties of work material`
Introduction Continued…

6. Literature Review
Author Year Inferences
Smith GV 1975
3D tool when applied for complex shapes together
with high penetration depth restricts the removal of
debris causing the abnormal discharge, so that only
60% of useful machining time is obtained
De Bruyn, HE,
Pekelharing AJ,
Delft TH
1980
Surface finish depends on generator setting and tool
surface area. Smaller machining surface results in
better surface finish
Weller EJ 1984 3D form tools associated with low MRR and high TWR

7. Literature Review continued…
Author Year Inferences
Soni JS,
Chakraverti G.
1994
Better flushing condition is reported by introducing
electrode rotation
Wong YS, Lim LC,
Lee LC
1995
MRR is highly affected by types of dielectric and
method of flushing
Yu ZY, Masuzawa T,
Fujino M
1998
Presented a new method, called uniform wear
method. Uniform wear at the end of the electrode
is realized and original shape is maintained.(For
micro molds)
Yan BH, Wang CC 1999
Both MRR and TWR considerably increases for tube
electrode in comparison to solid electrode

8. Literature Review continued…
Author Year Inferences
Wang CC, Yan BH 2000
Better flushing condition is reported by introducing
electrode rotation
Kunieda M, Muto H 2000
Twin and multi spark electrode discharge system,
the MRR and energy efficiency were found higher
than conventional EDM process
Mohan B, Rajadurai A,
Satyanarayan KG
2002
Flushing condition is improved by tube electrode
design
Mohan B, Rajadurai A,
Satyanarayana KG
2004
Flushing condition is improved by rotary tube
electrode design

9. Literature Review continued…
Author Year Inferences
Bayramoglu M,
Duffill AW
2004
The application of plate type tools results in high MRR
and high TWR, also have good dimensional accuracy
and surface finish
Sohani MS,
Gaitonde VN,
Siddeswarappa B,
Deshpande AS
2009
3D solid form tool with different geometries revealed
that best tool shape for high MRR and TWR is circular
in shape, followed by triangular, rectangular and
square cross sections.
Author Year Inferences
Bayramoglu M,
Duffill AW
2004
The application of plate type tools results in high MRR
and high TWR, also have good dimensional accuracy
and surface finish
Sohani MS,
Gaitonde VN,
Siddeswarappa B,
Deshpande AS
2009
3D solid form tool with different geometries revealed
that best tool shape for high MRR and TWR is circular
in shape, followed by triangular, rectangular and
square cross sections.

10. Problem Identification
 In 3D form tools, not much work is done on the use of different tool cross-
sectional geometries like rectangular, triangular etc. on performance
measure like MRR, EWR etc.
 Most of research work in EDM relates to use of 3D form tool. Alternate
types of tools like frame type and plate type are yet to be tried for work-
tool interfaces.
 No work is available on comparative study of various electrode designs
and electrodes manufactured by different techniques with same/different
work materials.

11. METHODOLOGY
Literature Survey
Types of tool Electrodes (Solid,
Hollow, Plate and frame)
Tool electrode manufacturing
methods
Problem Identification
Experiments on EDM
Machine using the
manufactured tool electrode
Discussion on the findings
Conclusion
Design and manufacture
of tool Electrode
Selection of tool electrode type
Selection of tool electrode
manufacturing method

12. Proposed Outcomes
 Suitable tool electrode type can be found for EDM process for complex
shapes on AISI H13 tool steel.
 MRR can be increased and TWR can be decreased by suitable design and
manufacturing methods .
 Surface roughness can also be improved.
 Recommended type of tool and its manufacturing methods corresponding
to the requirement can be identified.

13. 1. Smith GV (1975) The level of development in EDM. IEE Conf. Electrical Meth.
Mach. Form. 133 : 101.
2. De Bruyn, HE, Pekelharing AJ, Delft TH (1980) Comparison of various erosion
systems with rectangular and trapezoidal pulse forms‘, CIRP Annals -
Manufacturing Technology 29(1): 103-106
3. Weller EJ (1984) Nontraditional Machining Processes. Society of Manufacturing
Engineers: 61
4. Soni JS, Chakraverti G. (1994) Machining characteristics of titanium with rotary
electro-discharge Machining. Wear 171: 51–58.
5. Wong YS, Lim LC, Lee LC (1995) Effect of flushing on electro-discharge machined
surfaces
6. Yu ZY, Masuzawa T, Fujino M (1998) Micro-EDM for three-dimensional cavities-
development of uniform wear method. Annals of the CIRP 47 (1): 169-172.
7. Yan BH, Wang CC (1999) The machining characteristics of Al2O3/6061Al
composite using rotary electro-discharge machining with a tube electrode. J
Mater Process Technol 95: 222-231.
8. Wang CC, Yan BH (2000) Blind-hole drilling of Al2O3/6061Al composite using
rotary electro-discharge machining. J Mater Process Technol, 102: 90–102.
REFERENCES

14. 8. Kunieda M, Muto H (2000) Development of multi-spark EDM. Ann. CIRP 49 (1):
119–122.
9. Mohan B, Rajadurai A, Satyanarayan KG (2002) Effect of SiC and rotation of
electrode on electric discharge machining of Al-SiC composite. J Mater Process
Technol124: 297–304.
10. Mohan B, Rajadurai A, Satyanarayana KG (2004) Electric discharge machining of
Al–SiC metal matrix composites using rotary tube electrode. J Mater Process
Technol 153–154: 978–985.
11. Bayramoglu M, Duffill AW (2004) CNC EDM of linear and circular contours using
plate tools. J Mater Process Technol 148:196–203.
12. Sohani MS, Gaitonde VN, Siddeswarappa B, Deshpande AS (2009) Investigations
into the effect of tool shapes with size factor consideration in sink electrical
discharge machining.
REFERENCES