INTERNATIONALMechanical Engineering and Technology (IJMET), ISSN 0976 – International Journal of JOURNAL OF MECHANICAL ENG...
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) V...
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) V...
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) V...
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) V...
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) V...
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Process parameters optimization for surface roughness in edm for aisi d2 steel

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Process parameters optimization for surface roughness in edm for aisi d2 steel

  1. 1. INTERNATIONALMechanical Engineering and Technology (IJMET), ISSN 0976 – International Journal of JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEME AND TECHNOLOGY (IJMET)ISSN 0976 – 6340 (Print)ISSN 0976 – 6359 (Online)Volume 4, Issue 1, January- February (2013), pp. 203-208 IJMET© IAEME: www.iaeme.com/ijmet.aspJournal Impact Factor (2012): 3.8071 (Calculated by GISI)www.jifactor.com ©IAEME PROCESS PARAMETERS OPTIMIZATION FOR SURFACE ROUGHNESS IN EDM FOR AISI D2 STEEL BY RESPONSE SURFACE METHODOLOGY 1 2 3 P.B.Wagh , R.R.Deshmukh , S.D.Deshmukh 1 (Sr, Lect. COE Osmanabad, prajotwagh71@gmail.com) 2 (Prof. J.N.E.C Aurangabad) 3 (Principal J.N.E.C Aurangabad) ABSTRACT In this investigation, response surface methodology (RSM) is used to investigate the effect of four controllable input variables namely: discharge current, pulse duration, pulse off time and gape voltage on material removal rate (MRR). A face centred central composite design matrix is used to conduct the experiments on AISI D2 with copper electrode. The response is modelled using RSM on experimental data. The significant coefficients are obtained by performing analysis of variance (ANOVA) at 95% confidence level. It is found that discharge current and pulse duration are significant factors. RSM is a precision methodology that needs only 31 experiments to assess the conditions. Keywords: Electrical discharge machining; EDM; Material removal rate; RSM; etc 1. INTRODUCTION Electrical Discharge Machining (EDM) is an unconventional manufacturing process based on removal of material from a part by means of a series of repeated electrical sparks created by electric pulse generators at short intervals between an electrode tool and the part to be machined immersed in dielectric fluid. At present, EDM is a widespread technique used in industry for high precision machining of all types of conductive materials such as metallic alloys, metals, graphite, composite materials or some ceramic materials. The selection of optimized manufacturing conditions is one of the most important aspects to consider in the die sinking electrical discharge machining (EDM) of conductive steel, as these conditions are 203
  2. 2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEMEthe ones that are to determine such important characteristics: surface roughness, electrodes wear(EW) and material removal rate (MRR). In this paper, a study will be perform on the influence ofthe factors of peak current, pulse on time, interval time and power supply voltage.2. EXPERIMENTAL WORK2.1 Experimental Setup Figure 1. EDM machineFor this experiment the whole work is done by using Electric Discharge Machine, modelELECTRONICA- ELECTRAPULS PS 50ZNC (die-sinking type), having provision ofprogramming in the Z-vertical axis and manually operated X and Y axes. The tool is made ofcathode and the work piece as anode. Commercial grade EDM oil (specific gravity= 0.763 kg/m3), freezing point= 94°C) was used as dielectric fluid with lateral flushing (pressure of 0.3kgf/cm2) system for effective flushing of machining debris from working gap region.2.2 selection of work piece The material AISI D2 (American Iron Steel Institute D2) is high carbon high chromiumnon shrinking water hardening die steel material. The selected material is of 20mm diameter and250mm long. It is cut into pieces of size 20mm diameter and 5mm length for experimentation.2.2.1Composition of AISI D2 material Element Composition weight (%) C 1.5 Mn 0.3 Si 0.3 Cr 12 Ni 0.3 CO 1.00 V 0.8 Fe Remaining Table 1Composition of AISI D2 material2.3 selection of tool electrode A cylindrical shaped pure copper of diameter 12mm is used for machining of AISI D2material. 204
  3. 3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEME2.4 selections of process parameters factor/level (coding) -2 -1 0 1 2 Discharge current 2 6 10 14 18 Spark on time 20 40 60 80 100 Spark off time 2 4 6 8 10 Spark gap 0.05 0.0875 0.125 0.1625 0.2 Table 2 levels of process parameters3. EXPERIMENTAL RESULTS FOR MATERIAL REMOVAL RATE FOR MATERIAL AISI D2 Run Ip Ton Toff S.G Wjb Wja Machini density (A) (µs) (µs) (mm) (gm) (gm) ng time (gm/mm3) (sec) (mm3/mim) 1 14 80 8 0.0875 16.9 16.33 5 0.0077 14.8050 2 18 60 6 0.125 14.34 13.56 5 0.0077 20.2727 3 14 40 8 0.0875 15.83 15.18 5 0.0077 17.0120 4 14 80 4 0.1625 15.56 14.85 5 0.0077 18.4420 5 10 60 6 0.125 16.61 16.10 5 0.0077 13.1820 6 6 80 8 0.1625 13.9 13.62 5 0.0077 7.3760 7 10 60 6 0.125 16.63 16.21 5 0.0077 11.0380 8 6 40 4 0.1625 19.45 19.08 5 0.0077 9.5840 9 10 60 6 0.125 18.94 18.46 5 0.0077 12.3376 10 6 80 4 0.1625 15.07 14.83 5 0.0077 6.1168 11 10 60 6 0.05 17.25 16.75 5 0.0077 12.9610 12 10 20 6 0.125 16.30 15.71 5 0.0077 15.3120 13 14 40 8 0.1625 15.12 14.45 5 0.0077 17.4280 14 10 60 6 0.125 17.18 16.70 5 0.0077 12.4670 15 10 60 6 0.125 14.81 14.31 5 0.0077 13.1030 16 6 80 8 0.0875 15.73 15.57 5 0.0077 4.1558 17 6 80 4 0.0875 15.27 15.02 5 0.0077 6.5974 18 10 60 6 0.125 15.44 15.02 5 0.0077 11.0380 19 6 40 4 0.0875 15.49 15.25 5 0.0077 6.3640 20 10 100 6 0.125 15.36 15.00 5 0.0077 9.3506 21 14 40 4 0.0875 15.77 15.12 5 0.0077 17.0120 22 10 60 6 0.2 17.33 16.92 5 0.0077 10.6490 23 14 80 4 0.0875 20.34 19.72 5 0.0077 15.9740 24 10 60 6 0.125 14.35 13.91 5 0.0077 11.4280 25 6 40 8 0.1625 14.56 14.31 5 0.0077 6.4200 26 14 80 8 0.1625 16.55 15.93 5 0.0077 16.2200 27 6 40 8 0.0875 16.06 15.86 5 0.0077 5.1940 28 10 60 10 0.125 17.35 16.86 5 0.0077 12.7660 29 14 40 4 0.1625 14.20 13.56 5 0.0077 16.4940 30 2 60 6 0.125 17.61 17.52 5 0.0077 2.2597 31 10 60 2 0.125 15.52 15.02 5 0.0077 13.1298 205
  4. 4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEME Table 3 Experimental results for Material removal rate for Material AISI D2 M a in E ffe c t s P lo t ( d a t a m e a n s ) fo r M R R Ip T on 20 15 10 5 Mean of MRR 0 2 6 10 14 18 20 40 60 80 100 T off SG 20 15 10 5 0 2 4 6 8 10 0 .0 5 0 0 0 .0 87 5 0 .1 2 5 0 0.1625 0 .2 00 0 Graph 1 Effect of machining parameters on MRR4 RESPONSE OPTIMIZATION Response Goal Lower Target MRR Maximum 0 20.277 Optimal Ip Ton Toff SG Hi 18.0 100.0 10.0 0.20 D Cur [18.0] [20.0] [2.0] [0.050] 1.0000 Lo 2.0 20.0 2.0 0.050 MRR Maximum y = 23.2978 d = 1.0000 Graph 2 D- Optimality plotFrom this graph we can predict the optimum values of process parameters Process parameters units Optimum values Discharge current (Ip) A 18 Spark on time (Ton) µs 20 Spark off time (Toff) µs 2 Spark gap (SG) mm 0.05 Table 4 optimum values of process parameters 206
  5. 5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEMEConfirmation test and their comparison with results Trial Optimum Ra (µm) Error No. conditions Experimental Predicted (%) 01 Ip=18 A, Ton =20 µs, Toff = 22.783 23.2978 2.20 2 µs, SG = 0.05mm 02 Ip=18 A, Ton =20 µs, Toff = 22.970 23.2978 1.40 2 µs, SG = 0.05mm Table 5 Confirmation test and their comparison with results5. CONCLUSION The choice of the electrical parameters of the EDM process depends largely on thematerial combination of the electrode and the work piece and the EDM manufactures onlysupply these parameters for a limited amount of material combinations.The industrialist can directly use the optimum values so that the material removal rate will bemaximum.MINITAB software was used for DOE and analysis of the experimental result and theresponse was validated experimentally.6. REFERENCES[1] Manish Vishwakarma, v.K.Khare, vishal Parashar, Response surface approach foroptimization of Sinker Electric Discharge Machine process parameters on AISI 4140 alloysteel; International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com, Vol. 2, Issue 4, July-August 2012, pp.185-189.[2] Md. Ashikur Rahman Khan, M.M. Rahman1, K. Kadirgama1, M.A. Maleque and M.Ishak, Prediction of Surface Roughness of Ti-6al-4v In Electrical Discharge Machining: ARegression Model, Journal of Mechanical Engineering and Sciences (JMES) e-ISSN: 2231-8380; Volume 1, pp. 16-24, December 2011.[3] M.K. Pradhan and C.K. Biswas, Effect of process parameters on surface roughness inEDM of tool steel by response surface methodology; Int. J. Precision Technology, Vol. 2, No.1, 2011[4] Mohan Kumar Pradhan and Chandan Kumar Biswas, Modelling of machining parametersfor MRR in EDM using response surface methodology, Proceedings of NCMSTA’08Conference National Conference on Mechanism Science and Technology: from Theory toApplication November 13-14, 2008 National Institute of Technology, Hamirpur[5] B. C. Routara, P. Sahoo, A. Bandyopadhyay, Application Of Response Surface MethodFor Modelling Of Statistical Roughness Parameters On Electric Discharge Machining.[6] Rodge M.K, Sarpate S.S and Sharma S.B, “Investigation On Process Response AndParameters In Wire Electrical Discharge Machining Of Inconel 625” International Journal ofMechanical Engineering & Technology (IJMET), Volume 4, Issue 1, 2013, pp. 54 - 65,Published by IAEME. 207
  6. 6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 1, January - February (2013) © IAEME[7] Mane S.G. and Hargude N.V., “An Overview Of Experimental Investigation Of Near DryElectrical Discharge Machining Process” International Journal Of Advanced Research InEngineering & Technology (IJARET), Volume 3, Issue 2, 2012, pp. 22 - 36, Published byIAEME.[8] M Manohar, Jomy Joseph, T Selvaraj and D Sivakumar, “Development Of Models UsingGenetic Programming For Turning Inconel 718 With Coated Carbide Tools”, InternationalJournal of Design and Manufacturing Technology (IJDMT), Volume 4, Issue 1, 2013,pp. 1 - 13, Published by IAEME.[9] Kirankumar Ramakantrao Jagtap, S.B.Ubale and Dr.M.S.Kadam, “Optimization OfCylindrical Grinding Process Parameters For AISI 5120 Steel Using Taguchi Method”,International Journal of Design and Manufacturing Technology (IJDMT), Volume 2, Issue 1,2011, pp. 47 - 56, Published by IAEME.[10] K. Leo Dev Wins and A. S. Varadarajan., “Optimization Of Surface Finish DuringMilling Of Hardened AISI4340 Steel With Minimal Pulsed Jet Of Fluid Application UsingResponse Surface Methodology” International Journal Of Advanced Research In Engineering& Technology (IJARET), Volume 2, Issue 1, 2011, pp. 12 - 28, Published by IAEME.[11] Kirankumar Ramakantrao Jagtap, S.B.Ubale and Dr.M.S.Kadam, “Optimization OfCylindrical Grinding Process Parameters For AISI 1040 Steel Using Taguchi Method”International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 1,2012, pp. 226 - 234, Published by IAEME.[12] Brij Bhushan Tyagi, Mohd.Parvez, Rupesh Chalisgaonkar and Nitin Sharma,“Optimization of Process Parameters of Wire Electrical Discharge Machining of AISI 316L”International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2,2012, pp. 317 - 327, Published by IAEME. 208

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