This document summarizes a research study on enhancing electrical discharge machining (EDM) of AISI H13 steel using copper electrodes that were processed via equal channel angular pressing (ECAP). Experiments were conducted using bare copper electrodes and ECAP-processed copper electrodes to compare their machining characteristics. The ECAP-processed electrodes demonstrated improved performance with a 27.7% higher rate of machining, 10.8% lower rate of tool erosion, and 26.6% lower surface roughness compared to bare copper electrodes.
Optimization of MRR in EDM Process with Different Job Material i.e Stainless ...IJERA Editor
Electro discharge machining (EDM) has been recognized as an efficient method of producing dies and machining of hard material such as ceramics and high strength metal matrix composites for the modern metal industry (1). In this process the metal are remove through melting or vaporization of job metal by high frequency spark discharge. Although in this process the metal removal rate is lower than the other non-conventional machining process. But the dimensional accuracy is higher than the other process and more complex shape can be produce generally composite material are fascinated as thy exhibit exceptional mechanical and physical properties such as high strength, high hardness, and high density at elevated temperature. For this extra ordinary behavior it has wide range of application on the metal industries like aerospace, dies or mould making industries, automobiles industries etc. The metal removal rate (M.R.R.) and surface smoothness not only depend on the selection of tool material also depend on the number of input parameter (such-input current, voltage, spindle speed, duty factor, dielectric medium), job metal property (conductivity ,hardness, strength, density etc.),machine condition and machining condition(machine performances, temperature, depth of cut or area of cut etc.). It is most difficult to select machining condition for optimal performances due to large number of parameters and inherent complexity of material removal mechanism taking place in EDM process. In the present work, the experiments were conducted using Taguchi L9 orthogonal approach, to ascertain the effect of EDM process parameters on material removal rate (MRR) of stain less steel and cast iron by using tool material such copper and graphite.
A Comparative Study to Maximize MRR in Electro Discharge Machining Process by...IJERA Editor
Electro Discharge Machining (EDM) is a non-traditional machining process, based on thermo electric energy between the work piece and electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. Electro Discharge Machine which has the ability to machine hard, difficult to machine material and parts with internal complex shape by using precisely controlled sparks that occurs between electrode and work piece in the presence of dielectric fluid. This spark removes material from both work piece and electrode. Material Removal Rate (MRR) is of crucial importance in this process. In this research experiment has been done along with Copper and Graphite tool material as well as Mild Steel and Aluminium material has been used as work piece. Three major Parameters named as Electrode Speed (V), Current (I), and Depth of Cut (h) are considered to determine the MRR. In this experiment three levels of each parameter has been taken by using Taguchi L9 orthogonal array to find out the best combination of electrode and work piece at the optimal setting of control parameters for maximum Material Removal Rate.
EDM machining is used for very hard and complex cutting of conducting materials with
higher surface finish and close dimensions. EDM process parameters are affected by both electrical
and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on
electro discharge machine with copper as cutting tool electrode. This paper presents the effect of
control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge
Machine. In this paper both the electrical factors and non electrical factors has been focused which
governs MRR and EWR. Paper is based on Design of experiment and optimization of EDM process
parameters. The technique used is Taguchi technique which is a statistical decision making tool helps
in minimizing the number of experiments and the error associated with it. The research showed that
the Pulse off time, Current has significant effect on material removal rate and electrode wear rate
respectively
Electro Discharge Machining (EDM) is a
non-traditional machining process, based on thermo electric
energy between the work piece and electrode. In this process,
the material removal is occurred electro thermally by a series
of successive discrete discharges between electrode and the
work piece. Electro Discharge Machine which has the ability to
machine hard, difficult to machine material and parts with
internal complex shape by using precisely controlled sparks
that occurs between electrode and work piece in the presence
of dielectric fluid. This spark removes material from both work
piece and electrode. Material Removal Rate (MRR) is of
crucial importance in this process. In this research experiment
has been done along with Copper and Graphite tool material as
well as Mild Steel and Aluminium material has been used as
work piece. Three major Control Parameters named as
Electrode Speed (V), Current (I) and Depth of Cut (h) are
considered to determine their influence on MRR. In this
experiment three levels of each parameter has been taken and
an analysis has been made to find out the influence of control
parameters on MRR using S/N Ratio and ANOVA Analysis
Optimization of MRR in EDM Process with Different Job Material i.e Stainless ...IJERA Editor
Electro discharge machining (EDM) has been recognized as an efficient method of producing dies and machining of hard material such as ceramics and high strength metal matrix composites for the modern metal industry (1). In this process the metal are remove through melting or vaporization of job metal by high frequency spark discharge. Although in this process the metal removal rate is lower than the other non-conventional machining process. But the dimensional accuracy is higher than the other process and more complex shape can be produce generally composite material are fascinated as thy exhibit exceptional mechanical and physical properties such as high strength, high hardness, and high density at elevated temperature. For this extra ordinary behavior it has wide range of application on the metal industries like aerospace, dies or mould making industries, automobiles industries etc. The metal removal rate (M.R.R.) and surface smoothness not only depend on the selection of tool material also depend on the number of input parameter (such-input current, voltage, spindle speed, duty factor, dielectric medium), job metal property (conductivity ,hardness, strength, density etc.),machine condition and machining condition(machine performances, temperature, depth of cut or area of cut etc.). It is most difficult to select machining condition for optimal performances due to large number of parameters and inherent complexity of material removal mechanism taking place in EDM process. In the present work, the experiments were conducted using Taguchi L9 orthogonal approach, to ascertain the effect of EDM process parameters on material removal rate (MRR) of stain less steel and cast iron by using tool material such copper and graphite.
A Comparative Study to Maximize MRR in Electro Discharge Machining Process by...IJERA Editor
Electro Discharge Machining (EDM) is a non-traditional machining process, based on thermo electric energy between the work piece and electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. Electro Discharge Machine which has the ability to machine hard, difficult to machine material and parts with internal complex shape by using precisely controlled sparks that occurs between electrode and work piece in the presence of dielectric fluid. This spark removes material from both work piece and electrode. Material Removal Rate (MRR) is of crucial importance in this process. In this research experiment has been done along with Copper and Graphite tool material as well as Mild Steel and Aluminium material has been used as work piece. Three major Parameters named as Electrode Speed (V), Current (I), and Depth of Cut (h) are considered to determine the MRR. In this experiment three levels of each parameter has been taken by using Taguchi L9 orthogonal array to find out the best combination of electrode and work piece at the optimal setting of control parameters for maximum Material Removal Rate.
EDM machining is used for very hard and complex cutting of conducting materials with
higher surface finish and close dimensions. EDM process parameters are affected by both electrical
and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on
electro discharge machine with copper as cutting tool electrode. This paper presents the effect of
control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge
Machine. In this paper both the electrical factors and non electrical factors has been focused which
governs MRR and EWR. Paper is based on Design of experiment and optimization of EDM process
parameters. The technique used is Taguchi technique which is a statistical decision making tool helps
in minimizing the number of experiments and the error associated with it. The research showed that
the Pulse off time, Current has significant effect on material removal rate and electrode wear rate
respectively
Electro Discharge Machining (EDM) is a
non-traditional machining process, based on thermo electric
energy between the work piece and electrode. In this process,
the material removal is occurred electro thermally by a series
of successive discrete discharges between electrode and the
work piece. Electro Discharge Machine which has the ability to
machine hard, difficult to machine material and parts with
internal complex shape by using precisely controlled sparks
that occurs between electrode and work piece in the presence
of dielectric fluid. This spark removes material from both work
piece and electrode. Material Removal Rate (MRR) is of
crucial importance in this process. In this research experiment
has been done along with Copper and Graphite tool material as
well as Mild Steel and Aluminium material has been used as
work piece. Three major Control Parameters named as
Electrode Speed (V), Current (I) and Depth of Cut (h) are
considered to determine their influence on MRR. In this
experiment three levels of each parameter has been taken and
an analysis has been made to find out the influence of control
parameters on MRR using S/N Ratio and ANOVA Analysis
Optimization of Weld Bead Geometry in Submerged Arc Welds Deposited On En24 S...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
A Study of Hole Drilling on Stainless Steel AISI 431 by EDM Using Brass Tube ...drboon
When a depth hole is drilled by EDM, taper is occurred which is not desired in the process. This research was focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431. The considered factors consist of electrical current, on-time, duty factor, water pressure and servo rate. The experimental results reveal that MRR increases when increasing of servo rate. The taper of hole increases with increasing of electrical current and servo rate. However, it is reverse proportion to water pressure and duty factor.
Electric discharge machining with analysis of variancePBR VITS
It defines and clarifies the experimental investigation on HSS steel material by using die sinker EDM.It is very helpful to the users who are waiting for the experimental analysis of the readings which is taken.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
In this investigation, experimental work and computational work are combined to obtain
improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means
of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel
alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time
(Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this
project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The
surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer
is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are
fed to the Minitab software and optimum input parameters for the desired output parameters are
identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of
effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is
performed in order to remove the recast layer and again the surface roughness is measured by using
stylus type roughness tester. Finally from the obtained results it was found that there was significant
improvement in the Surface roughness of the nickel alloy material. In addition using regression
analysis this work is stimulated by computational method and the results are obtained.
Optimization of edm for mrr of inconel 600 using taguchi methodsushil Choudhary
Electrical discharge machining (EDM) process is convert electrical energy into heat energy between the work piece and tool electrode in the presence of dielectric fluid like, EDM oil, to process conductive difficult-to-machine materials. EDM process is has been applicable in the machining of hard, brittle and all kinds of electric conductive materials. This process widely used for produces die making, mould making, complex shapes, deep holes and other geometrical shapes as per desire. Inconel 600 super alloy materials widely used in various types of industries such as: aerospace, aircraft, nuclear, food processing, pulp manufacturing, automobiles industry etc. In this study, investigations on the effect of process parameters on machining of Inconel 600 super alloy material. Tungsten carbide material used as tool electrode and EDM oil used as dielectric fluid. The effects of input process parameters such as pulse-on-time, peak current and gap voltage on performance measure material removal rate was investigated using Taguchi method. MRR is lineally increases with the increase in peak current during the EDM process. MRR is increases with the increase in gap voltage. Initially MRR increases with increase in pulse on time then decreases with the increase of pulse on time.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950‟s and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
Optimization of Weld Bead Geometry in Submerged Arc Welds Deposited On En24 S...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
A Study of Hole Drilling on Stainless Steel AISI 431 by EDM Using Brass Tube ...drboon
When a depth hole is drilled by EDM, taper is occurred which is not desired in the process. This research was focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431. The considered factors consist of electrical current, on-time, duty factor, water pressure and servo rate. The experimental results reveal that MRR increases when increasing of servo rate. The taper of hole increases with increasing of electrical current and servo rate. However, it is reverse proportion to water pressure and duty factor.
Electric discharge machining with analysis of variancePBR VITS
It defines and clarifies the experimental investigation on HSS steel material by using die sinker EDM.It is very helpful to the users who are waiting for the experimental analysis of the readings which is taken.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
In this investigation, experimental work and computational work are combined to obtain
improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means
of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel
alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time
(Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this
project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The
surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer
is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are
fed to the Minitab software and optimum input parameters for the desired output parameters are
identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of
effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is
performed in order to remove the recast layer and again the surface roughness is measured by using
stylus type roughness tester. Finally from the obtained results it was found that there was significant
improvement in the Surface roughness of the nickel alloy material. In addition using regression
analysis this work is stimulated by computational method and the results are obtained.
Optimization of edm for mrr of inconel 600 using taguchi methodsushil Choudhary
Electrical discharge machining (EDM) process is convert electrical energy into heat energy between the work piece and tool electrode in the presence of dielectric fluid like, EDM oil, to process conductive difficult-to-machine materials. EDM process is has been applicable in the machining of hard, brittle and all kinds of electric conductive materials. This process widely used for produces die making, mould making, complex shapes, deep holes and other geometrical shapes as per desire. Inconel 600 super alloy materials widely used in various types of industries such as: aerospace, aircraft, nuclear, food processing, pulp manufacturing, automobiles industry etc. In this study, investigations on the effect of process parameters on machining of Inconel 600 super alloy material. Tungsten carbide material used as tool electrode and EDM oil used as dielectric fluid. The effects of input process parameters such as pulse-on-time, peak current and gap voltage on performance measure material removal rate was investigated using Taguchi method. MRR is lineally increases with the increase in peak current during the EDM process. MRR is increases with the increase in gap voltage. Initially MRR increases with increase in pulse on time then decreases with the increase of pulse on time.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950‟s and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
Operation “Blue Star” is the only event in the history of Independent India where the state went into war with its own people. Even after about 40 years it is not clear if it was culmination of states anger over people of the region, a political game of power or start of dictatorial chapter in the democratic setup.
The people of Punjab felt alienated from main stream due to denial of their just demands during a long democratic struggle since independence. As it happen all over the word, it led to militant struggle with great loss of lives of military, police and civilian personnel. Killing of Indira Gandhi and massacre of innocent Sikhs in Delhi and other India cities was also associated with this movement.
Students, digital devices and success - Andreas Schleicher - 27 May 2024..pptxEduSkills OECD
Andreas Schleicher presents at the OECD webinar ‘Digital devices in schools: detrimental distraction or secret to success?’ on 27 May 2024. The presentation was based on findings from PISA 2022 results and the webinar helped launch the PISA in Focus ‘Managing screen time: How to protect and equip students against distraction’ https://www.oecd-ilibrary.org/education/managing-screen-time_7c225af4-en and the OECD Education Policy Perspective ‘Students, digital devices and success’ can be found here - https://oe.cd/il/5yV
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
This is a presentation by Dada Robert in a Your Skill Boost masterclass organised by the Excellence Foundation for South Sudan (EFSS) on Saturday, the 25th and Sunday, the 26th of May 2024.
He discussed the concept of quality improvement, emphasizing its applicability to various aspects of life, including personal, project, and program improvements. He defined quality as doing the right thing at the right time in the right way to achieve the best possible results and discussed the concept of the "gap" between what we know and what we do, and how this gap represents the areas we need to improve. He explained the scientific approach to quality improvement, which involves systematic performance analysis, testing and learning, and implementing change ideas. He also highlighted the importance of client focus and a team approach to quality improvement.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
Ethnobotany and Ethnopharmacology:
Ethnobotany in herbal drug evaluation,
Impact of Ethnobotany in traditional medicine,
New development in herbals,
Bio-prospecting tools for drug discovery,
Role of Ethnopharmacology in drug evaluation,
Reverse Pharmacology.
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
Model Attribute Check Company Auto PropertyCeline George
In Odoo, the multi-company feature allows you to manage multiple companies within a single Odoo database instance. Each company can have its own configurations while still sharing common resources such as products, customers, and suppliers.
We all have good and bad thoughts from time to time and situation to situation. We are bombarded daily with spiraling thoughts(both negative and positive) creating all-consuming feel , making us difficult to manage with associated suffering. Good thoughts are like our Mob Signal (Positive thought) amidst noise(negative thought) in the atmosphere. Negative thoughts like noise outweigh positive thoughts. These thoughts often create unwanted confusion, trouble, stress and frustration in our mind as well as chaos in our physical world. Negative thoughts are also known as “distorted thinking”.
1. Enhancing Electrical Discharge Machining Process Characteristics
On AISI H13 Steel Using
Equal Channel Angular Pressed Copper Electrode
Gopal . R
[Reg. No. 15JAN/MECH/PH.D.PT/002]
Research Scholar, Department of Mechanical Engineering,
Karpagam Academy of Higher Education, Coimbatore-641 021
Under the Guidance of
Dr.K.Thirunavukkarasu
Professor, Dept.of Mechamical Engineering
Karpagam Academy of Higher Education
Coimbatore - 641 021.
08.12.2018 KAHEARC 2018 Slide No. 1
2. Activities I Year -2015 II Year-2016 III Year-2017 IV Year-2018
Course work
completed YES
Literature Review COMPLETED
Problem Identified YES
Methodology COMPLETED
Experimentation COMPLETED
Results &
Discussion
COMPLETED
No. of publications - - 2 papers
communicated
PRESENT STATUS OF THE RESEARCH WORK
08.12.2018 KAHEARC 2018 Slide No. 2
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.
Applications
Mold making tool and die industries,
Aerospace,
Automobile and
Electronic industries
Turbo machinaries
08.12.2018 KAHEARC 2018 Slide No. 3
4. NATIONALAND INTERNATIONAL STATUS
Cherng Lin et al. (2000) integrated the mechanisms of EDM and ultrasonic machining to
improve the efficiency of machining. They found that the performance of EDM/USM is
higher than conventional EDM with distilled water.
Lin Gu et al. (2012) compared the performance of EDM process using solid electrode
and bundled electrode with multi hole. They concluded that the bundled electrode shows
higher ROM with lesser tool wear as it can endure high peak current. Also they found
that the flow velocity of fluid is increases from centre to outer radially.
Sony and chakraverti, (1994) tried to improve the machining performance by giving the
orbital motion to the electrode. They concluded that rate of machining is increase
significantly at constant wear ratio with the rotating electrode.
Ghoreishi and Atkinson combines the rotation and vibration to the electrode. They
developed a model through stepwise linear integration and found significant variables.
The combination of high frequency vibration and electrode rotation brings high rate of
machining with specified roughness
08.12.2018 KAHEARC 2018 Slide No. 4
5. Xu et al. (2009), proposed ultrasonic vibration assisted EDM in a gas medium in
machining cemented carbide, also proposed metal removing mechanisms such as melting
and evaporation, oxidation and decomposition, spalling, the force of high pressure gas and
the affection of ultrasonic vibration.
Samuel and philip (1997) analyzed the powder metallurgy electrodes. It is limited to
certain machining conditions as it deposits the powder on the work instead of machining.
Thangadurai and asha (2014) used the copper electrode to machine aluminium boran
carbide composite. They designed the experiment based on Box-Behnken approach and
developed mathematical model for rate of machining, rate of tool erosion and surface
coarseness. Also they optimized the parameters using genetic algorithm and desirability
function approach.
Mohan (2004) et al. used the solid and tube electrodes for machining Al-SiC metal matrix
composite. He concluded that the rotating tube electrode has better performance
characteristics than rotating solid electrode as it enhances the flushing
08.12.2018 KAHEARC 2018 Slide No. 5
NATIONALAND INTERNATIONAL STATUS
6. Marashi (2016)et al. found the electrode undergone single pass equal channel angular pressing
process, facilitate the reduction of tool erosion, surface crack formation and dimensional accuracy
on D2 steel.
Oliver Nesa Raj and Sethuramalingam Prabhu (2017) prepared a carbon nano tube infused copper
electrode for machining AISI D2 steel by taguchi method and they optimized the parameters using
TOPSIS method and found,it produces better surface characteristics and reduces the micro cracks
and white spots.
Saroj Kumar Padhi (2017) et al. fabricated the electrode for D2 steel using acrylonitrile butadine
sterane plastic by fused deposition modeling and electro plate the copper about 1000 micron
thickness. They found the rate of machining is not much affected, but considerable reduction in
tool erosion and roughness.
Kaveh Edalati et al. (2012) found equal channel angular pressing of pure copper showed negligible
change in electrical conductivity with increased hardness about 270% in the early stages
Estrin et al. after ECAP process the hardness and ultimate strength of copper is significantly
increases and also it reduces the electrical conductivity due to defects in crystal lattice as a result of
electron scattering
08.12.2018 KAHEARC 2018 Slide No. 6
NATIONALAND INTERNATIONAL STATUS
7. AISI H13
Dia 25 x 10 mm
52 HRC
Applications:
Standard material for hot forming tools
Extrusion tools
Forging dies
Pressure casting tool
Hot shear knives
Tools for plastic industry.
Element Content (%)
Carbon 0.32
Chromium 4.75
Manganese 0.2
Molybdenum 1.1
Phosphorus 0.03
Silicon 0.8
Sulphur 0.03
Vanadium 0.8
08.12.2018 KAHEARC 2018 Slide No. 7
WORK MATERIAL
8. Material : copper
Dia 12mm x 70mm length rod is ECAP processed
and sized into dia 12mm x 45mm length.
Another one bare copper electrode of dia 12mm x 45
mm length is prepared.
08.12.2018 KAHEARC 2018 Slide No. 8
ELECTRODE
9. DESIGN OF EXPERIMENTS
Fractional Factorial Design : Box Bhenken Approach
No of Parameters : 3
No. of levels : 3
No. Of experiments conducted : 17
Parameter Unit Codes
Level
-1 0 1
Peak Current (Ip) Ampere (amp) A 12 24 36
Spark existing
Time (SET)
Micro seconds
(μs)
B 100 550 1000
Spark absence time
(SAT)
Micro seconds
(μs)
C 100 550 1000
08.12.2018 KAHEARC 2018 Slide No. 9
11. Comparison of machining characteristics
0
0.0002
0.0004
0.0006
0.0008
0.001
0.0012
0.0014
0.0016
0.0018
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
BARE
ECAP
Rate of machining for bare and ECAP processed electrode
08.12.2018 KAHEARC 2018 Slide No. 11
12. Comparison of machining characteristics
0.0000000
0.0002000
0.0004000
0.0006000
0.0008000
0.0010000
0.0012000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
RTE BARE
RTE ECAP
Rate of tool erosion for bare and ECAP processed electrode
08.12.2018 KAHEARC 2018 Slide No. 12
13. Comparison of machining characteristics
0
0.5
1
1.5
2
2.5
3
3.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
SC BARE
SC ECAP
Surface coarseness for bare and ECAP processed electrode
08.12.2018 KAHEARC 2018 Slide No. 13
14. Optimization By Desirability Function Approach
Name Goal Lower Limit Upper Limit Importance
Current is in range 12 36 3
Spark existing
time
is in range 100 1000 3
Spark absence
time
is in range 100 1000 3
ROM maximize 0.0001265 / 0.00015 0.001511 / 0.000154 1
RTE minimize
0.0001095 / 8.719E-
005
0.001053 / 0.0008199 5
SC minimize 0.495338 / 0.257833 3.1916 / 2.64709 5
The objective function and the constrains for this problem can be written as
Max : f(x) = MRR
Min : f(x) = RTE
Min : f(x) = SC
Subjected to, 12 < = x1 > = 36 , 100 < = x2 > = 1000 and 100 < = x3 > = 100
08.12.2018 KAHEARC 2018 Slide No. 14
15. Optimized Vales For Control Variables And Responses
Electrod
e
Current
(A)
Spark
existing
time (μs)
Spark
absence
time (μs)
MRR
(g/s)
RTE
(g/s)
SC
(μm)
Desirability
Bare
electrode
12 816.37 100 0.000368925 0.000156913 0.618878 0.816
ECAP
electrode
14.76 100.01 493.54 0.0002666421 0.000140928 0.454246 0.742
Changes
in %
- - - 27.7 10.8 26.6
08.12.2018 KAHEARC 2018 Slide No. 15
16. Confirmative Test
Electrode
Rate of machining Rate of tool erosion Surface coarseness
Predicted Actual Error % Predicted Actual Error % Predicted Actual Error %
Bare
0.000369 0.000355 3.77448 0.000157 0.000152 3.131034 0.618878 0.59428 3.974612
ECAP
0.000267 0.000278 4.40966 0.000141 0.000137 2.645322 0.454246 0.43597 4.023371
08.12.2018 KAHEARC 2018 Slide No. 16
17. CONCLUSION
ECAP processed copper has better machining characteristics than bare
copper electrode.
Compared to bare copper electrode, the rate of machining is reduced up to
27.7% while machining with optimum values.
ECAP processed copper electrode reduces the rate of tool erosion and
surface coarseness by around 10% and 26% respectively.
The manufacturers can use the ECAP electrode for reducing the RTE and
SC for finishing process as it yields better shape and accuracy than bare
electrode.
08.12.2018 KAHEARC 2018 Slide No. 17
18. REFERENCES
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08.12.2018 KAHEARC 2018 Slide No. 18
19. REFERENCES
[8] B. Mohan, A. Rajadurai, K.G. Satyanarayana, Electric discharge machining of Al– SiC
metal matrix composites using rotary tube electrode, Journal of Materials Processing
Technology 153–154 (2004) 978–985.
[9] Marashi H, Jafarlou DM, Sarahan AAD, Mardi N.A.Employing severe plastic deformation to
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[10] S. Oliver Nesa Raj and Sethuramalingam Prabhu, Analysis of multi objective optimization
using TOPSIS method in EDM process with CNT infused copper electrode, Int. J. Machining
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[11] Saroj Kumar Padhi, S.S.Mahappatra and Harish Chandra Das, Performance of a Copper
Electroplated Plastic Electrical Discharge Machining Electrode Compared to a Copper
Electrode, International Journal of Pure and Applied Mathematics Volume 114 No. 7
2017, 459-469
[12] Kaveh Edalati, Kazutaka Imamura, Takanobu Kiss and Zenji Horita, Equal- Channel Angular
Pressing and High-Pressure Torsion of Pure Copper: Evolution of Electrical Conductivity
and Hardness with Strain, Materials Transactions, Vol. 53, No. 1 (2012) pp. 123 to 127
[13] C.F. Zhu, F.P. Du, Q.Y. Jiao, X.M. Wang, A.Y. Chen, F. Liu, D. Pan, Microstructure and
strength of pure Cu with large grains processed by equal channel angular pressing,
Materials and Design (2013), doi: http://dx.doi.org/10.1016/j.matdes.2013.05.029
08.12.2018 KAHEARC 2018 Slide No. 19
![Enhancing Electrical Discharge Machining Process Characteristics
On AISI H13 Steel Using
Equal Channel Angular Pressed Copper Electrode
Gopal . R
[Reg. No. 15JAN/MECH/PH.D.PT/002]
Research Scholar, Department of Mechanical Engineering,
Karpagam Academy of Higher Education, Coimbatore-641 021
Under the Guidance of
Dr.K.Thirunavukkarasu
Professor, Dept.of Mechamical Engineering
Karpagam Academy of Higher Education
Coimbatore - 641 021.
08.12.2018 KAHEARC 2018 Slide No. 1](https://image.slidesharecdn.com/4-230525072104-50897ee9/85/4-Research-Congress-Dec-2018-ppt-1-320.jpg)
