This document reviews optimization of dry electric discharge machining (EDM) process parameters. It discusses how dry EDM replaces liquid dielectric with gas, improving environmental friendliness. The literature review examines studies on how factors like voltage, current, and gas pressure affect material removal rate, surface roughness, and tool wear rate. Response surface methodology and algorithms like NSGA-II and genetic algorithms have been used to develop models and optimize the conflicting objectives of maximizing material removal rate while minimizing surface roughness. Overall, the document provides an overview of dry EDM optimization research aimed at improving process performance and efficiency.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
This document discusses optimization techniques used in electric discharge machining (EDM). EDM is a non-traditional machining process that uses electrical discharges to erode conductive materials. Key parameters that affect the EDM process include pulse on/off time, voltage, current, discharge energy, electrode polarity, and dielectric fluid. Optimization techniques aim to maximize material removal rate and tool wear ratio while minimizing surface roughness. The document reviews techniques like Taguchi methods, response surface methodology, genetic algorithms, neural networks, and grey relational analysis that have been used to optimize EDM for objectives like material removal rate, surface finish, and tool wear ratio.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
An overview of experimental investigation of near dry electrical discharge ma...iaemedu
This document provides an overview of experimental investigations into near-dry electrical discharge machining (EDM). Near-dry EDM uses a mixture of gas and small amount of dielectric liquid, making it more environmentally friendly than conventional wet EDM which uses large amounts of dielectric fluid. Near-dry EDM was found to have higher material removal rates than wet EDM at lower discharge energies and better surface finish quality than dry EDM. Several studies investigated the effects of EDM process parameters like discharge current, gap voltage, and pulse on time on material removal rate and surface roughness. However, more work is needed to optimize parameters to make near-dry EDM more cost-effective. The document reviews the limited existing studies on near
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
The detailed study of history features and benefits of wire electric discharg...IAEME Publication
1) The document discusses the history, features, and benefits of wire electric discharge machining (Wire EDM).
2) Wire EDM is a non-traditional machining process that uses electric sparks to erode materials like ceramics, super alloys, and composites that cannot be cut with traditional tools.
3) The process involves an electrically charged wire tool and a workpiece separated by a dielectric fluid. Repeated electric sparks are generated between the wire and workpiece, vaporizing small amounts of material and creating the cut.
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
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document presents a seminar report on dry and near dry electrical discharge machining (EDM). EDM uses electric sparks to erode material away from a conductive workpiece. Dry EDM replaces the liquid dielectric fluid with gas, which avoids issues with liquid fluids but causes lower material removal rates and tool overheating. Near dry EDM uses a liquid-gas mixture as the dielectric to improve material removal rates over dry EDM while avoiding debris deposition issues of wet EDM. The document discusses the EDM process, developments in dry and near dry EDM, their applications in prototype production and broken tool removal, and concludes that near dry EDM improves performance issues of dry EDM.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
This document discusses optimization techniques used in electric discharge machining (EDM). EDM is a non-traditional machining process that uses electrical discharges to erode conductive materials. Key parameters that affect the EDM process include pulse on/off time, voltage, current, discharge energy, electrode polarity, and dielectric fluid. Optimization techniques aim to maximize material removal rate and tool wear ratio while minimizing surface roughness. The document reviews techniques like Taguchi methods, response surface methodology, genetic algorithms, neural networks, and grey relational analysis that have been used to optimize EDM for objectives like material removal rate, surface finish, and tool wear ratio.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
An overview of experimental investigation of near dry electrical discharge ma...iaemedu
This document provides an overview of experimental investigations into near-dry electrical discharge machining (EDM). Near-dry EDM uses a mixture of gas and small amount of dielectric liquid, making it more environmentally friendly than conventional wet EDM which uses large amounts of dielectric fluid. Near-dry EDM was found to have higher material removal rates than wet EDM at lower discharge energies and better surface finish quality than dry EDM. Several studies investigated the effects of EDM process parameters like discharge current, gap voltage, and pulse on time on material removal rate and surface roughness. However, more work is needed to optimize parameters to make near-dry EDM more cost-effective. The document reviews the limited existing studies on near
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
The detailed study of history features and benefits of wire electric discharg...IAEME Publication
1) The document discusses the history, features, and benefits of wire electric discharge machining (Wire EDM).
2) Wire EDM is a non-traditional machining process that uses electric sparks to erode materials like ceramics, super alloys, and composites that cannot be cut with traditional tools.
3) The process involves an electrically charged wire tool and a workpiece separated by a dielectric fluid. Repeated electric sparks are generated between the wire and workpiece, vaporizing small amounts of material and creating the cut.
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
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document presents a seminar report on dry and near dry electrical discharge machining (EDM). EDM uses electric sparks to erode material away from a conductive workpiece. Dry EDM replaces the liquid dielectric fluid with gas, which avoids issues with liquid fluids but causes lower material removal rates and tool overheating. Near dry EDM uses a liquid-gas mixture as the dielectric to improve material removal rates over dry EDM while avoiding debris deposition issues of wet EDM. The document discusses the EDM process, developments in dry and near dry EDM, their applications in prototype production and broken tool removal, and concludes that near dry EDM improves performance issues of dry EDM.
Comparative study on variation of process characteristics on al and die steel...IAEME Publication
This document presents the results of an experimental study on the influence of electrical discharge machining (EDM) parameters on process characteristics when machining aluminum (Al) and die steel components. Specifically, it examines the effect of changing current on material removal rate, tool wear ratio, and surface roughness for the two materials. The results showed that increasing current from 10A to 20A led to higher material removal rates and tool wear ratios for both Al and die steel. It also resulted in increased surface roughness parameters (average roughness, average maximum height, maximum roughness depth) for the machined surfaces of both materials. The findings provide information on selecting optimal current parameters to achieve desired EDM efficiency and surface finish when machining Al and die steel
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
This document discusses various methods for improving material removal rate (MRR) in electrical discharge machining (EDM). It explains that EDM uses thermoelectric energy from electric sparks to remove material from conductive workpieces. MRR can be improved through electrode design and geometry, controlling process parameters like voltage, current, and pulse duration, using EDM variations with ultrasonic vibration or rotation, mixing powders into the dielectric fluid, using gas as the dielectric medium, and techniques like multi-spark EDM. Overall, MRR is an important performance measure that relies on empirical methods and requires further research due to the complex interrelationship between electrical and non-electrical parameters in the stochastic EDM process.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
This document provides a review of research on electrical discharge machining (EDM) of non-conductive ceramic materials. It discusses how ceramics can be made electrically conductive through doping with conductive materials like titanium carbide. It then summarizes several studies that investigated EDM of doped ceramics and the effects of process parameters on material removal rate and surface finish. It also describes an "assisting electrode method" where a conductive layer forms on the ceramic surface during EDM, allowing discharges and machining to occur even for insulating materials. The document aims to demonstrate the feasibility of EDM for machining ceramics and potential applications of this innovative processing technique.
This document provides an overview of machining non-conducting materials using electrochemical discharge phenomena, known as spark assisted chemical engraving (SACE). SACE allows machining of materials like glass and ceramics. It involves applying a voltage between a tool electrode and counter electrode in an electrolyte solution, causing electrochemical discharges that erode the workpiece material. While studied since the 1960s, SACE has not been widely applied industrially. The document reviews the state of knowledge on SACE and discusses challenges that have limited its use, such as inconsistent machining results due to the complex interactions between process parameters.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
Current Research development in Dry Electric Discharge Machining (DEDM): Revi...sushil Choudhary
Electrical discharge machining (EDM) has been
recognized as an efficient production method for precision
machining of electrically conducting hardened materials.
EDM in gaseous media is one of the fastest growing branches
among institutions involved in the research and development
of EDM as green manufacturing process Dry EDM is an
environmental friendly machining process were liquid
dielectric fluid is replaced by gaseous dielectric fluids. Present
& past performance of dry EDM process using various types
of gases & their mixtures as dielectric medium. The main
objective is to study the effect of pulse-on time, pulse-off time,
gap voltage, open voltage, servo voltage, discharge current;
polarity, pulse width, duty factor, gas or air pressure,
electrode rotation speed on Material removal Rate (MRR),
Surface Roughness (Ra) and Tool Wear Rate (TWR) also
discussed resulting finding condition for machining of
material depends on the optimization techniques or criteria.
Development of Dry EDM Technology enhance the
performance parameters such as material removal rate
(MRR), Low tool wear rate (TWR), thin recast layer.
A Literature Review On Dry Wire Electrical Discharge MachiningIJSRD
This document provides a literature review on dry wire electrical discharge machining (EDM). It summarizes several past studies that investigated dry EDM using various gases as dielectrics and how it improves performance over conventional EDM using liquid dielectrics. The review examines factors like material removal rate, surface finish, tool wear rate, and process parameters that influence these outputs. It discusses the basic working principles of dry wire EDM and evaluates the findings of multiple past studies on the effects of different machining variables in dry EDM.
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
1) A novel technique called double electrodes synchronous servo electrical discharge grinding (DESSEDG) is presented to machine non-conductive engineering ceramics with high efficiency and precision by integrating advantages of electrical discharge machining (EDM) and mechanical grinding.
2) In the DESSEDG process, a conductive grinding wheel rotates on the workpiece surface while a thin copper sheet electrode is automatically fed to the area where the wheel and workpiece meet, causing electrical discharges that erode the workpiece surface.
3) The eroded layer is then removed by the grinding wheel, combining the material removal of EDM with mechanical grinding for higher efficiency machining of hard non-conductive ceramics compared
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
This document is a project report submitted to Gujarat Technological University for their undergraduate program. It examines the experimental study of the effect of process parameters on the performance of electrical discharge machining (EDM). The project was conducted by four students under the guidance of a professor from the Mechanical Engineering department. The report includes certificates from the guide and examiners. It also acknowledges the help received. The abstract provides an overview of the focus of the project which is to analyze how current, voltage, pulse-on time and pulse-off time affect the material removal rate of the EDM process. The literature review covers past research conducted on improving the speed and accuracy of EDM as well as applying it to new materials.
This document provides a dissertation on investigating the machining characteristics of titanium alloy (Ti-6Al-4V) using the electrical discharge machining (EDM) process. The dissertation includes an introduction to traditional and non-traditional machining processes. It then focuses on EDM, including the history, types, principles, parameters, materials, advantages, and limitations. The methodology section describes the materials, equipment, experimental design using Taguchi methods, and parameters/levels studied. Results and discussions are presented on material removal rate, tool wear rate, surface roughness, and microhardness based on experiments. Finally, conclusions are drawn and scope for future work is discussed.
Study of process parameter of wire electric discharge machining the reviewIAEME Publication
This document summarizes the process parameters of wire electric discharge machining (WEDM). It discusses the key electrical parameters like pulse duration, pulse interval, servo voltage, and peak current. It also discusses the electrode wire parameters like wire size, material, tension and feed. Additionally, it covers dielectric fluid parameters and workpiece parameters that influence the WEDM process. The document provides details on how each parameter impacts material removal rate and machining characteristics.
The document is a project report submitted by four students to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The report investigates optimizing the wire electrical discharge machining (WEDM) process parameters using Taguchi methods and grey relational analysis. It includes sections on the introduction of WEDM, literature review, work undertaken including the experimental setup and design, results and discussion of optimizing material removal rate, surface roughness and electrode consumption, and conclusions. The goal is to determine the optimal process parameters to achieve higher machining rates with the desired accuracy and minimal surface damage using statistical analysis techniques.
Dynamic Monitoring Of Information in Large Scale Power GridsIJSRD
this document proposes the software model for detection and analysis of cascading faults in the operation of large scale power grids. Using data mining technologies, probable patterns can be detected for faults and proper mitigation measures can be taken. Firstly, the fault is detected by checking the stability of system. Then event sequences are calculated to best approximate the fault node. Then by analyzing the severity of vulnerability and region in which vulnerability would occur, proper ICT Technologies can make operators aware about the faults. Hence, speeding up the existing mechanisms. This model aims to solve problem of detection more efficiently than existing systems.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
This document summarizes a study that investigated the effect of process parameters on machining EN31 steel using electrical discharge machining (EDM). Experiments were conducted using different tool materials (copper, aluminum, and EN24), supply currents, flushing pressures, and pulse-on times. The experiments analyzed their influence on surface roughness, material removal rate, tool wear rate, and taper. The results of this study can help optimize the EDM process for machining EN31 steel.
Comparative study on variation of process characteristics on al and die steel...IAEME Publication
This document presents the results of an experimental study on the influence of electrical discharge machining (EDM) parameters on process characteristics when machining aluminum (Al) and die steel components. Specifically, it examines the effect of changing current on material removal rate, tool wear ratio, and surface roughness for the two materials. The results showed that increasing current from 10A to 20A led to higher material removal rates and tool wear ratios for both Al and die steel. It also resulted in increased surface roughness parameters (average roughness, average maximum height, maximum roughness depth) for the machined surfaces of both materials. The findings provide information on selecting optimal current parameters to achieve desired EDM efficiency and surface finish when machining Al and die steel
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
This document discusses various methods for improving material removal rate (MRR) in electrical discharge machining (EDM). It explains that EDM uses thermoelectric energy from electric sparks to remove material from conductive workpieces. MRR can be improved through electrode design and geometry, controlling process parameters like voltage, current, and pulse duration, using EDM variations with ultrasonic vibration or rotation, mixing powders into the dielectric fluid, using gas as the dielectric medium, and techniques like multi-spark EDM. Overall, MRR is an important performance measure that relies on empirical methods and requires further research due to the complex interrelationship between electrical and non-electrical parameters in the stochastic EDM process.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
This document provides a review of research on electrical discharge machining (EDM) of non-conductive ceramic materials. It discusses how ceramics can be made electrically conductive through doping with conductive materials like titanium carbide. It then summarizes several studies that investigated EDM of doped ceramics and the effects of process parameters on material removal rate and surface finish. It also describes an "assisting electrode method" where a conductive layer forms on the ceramic surface during EDM, allowing discharges and machining to occur even for insulating materials. The document aims to demonstrate the feasibility of EDM for machining ceramics and potential applications of this innovative processing technique.
This document provides an overview of machining non-conducting materials using electrochemical discharge phenomena, known as spark assisted chemical engraving (SACE). SACE allows machining of materials like glass and ceramics. It involves applying a voltage between a tool electrode and counter electrode in an electrolyte solution, causing electrochemical discharges that erode the workpiece material. While studied since the 1960s, SACE has not been widely applied industrially. The document reviews the state of knowledge on SACE and discusses challenges that have limited its use, such as inconsistent machining results due to the complex interactions between process parameters.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
Current Research development in Dry Electric Discharge Machining (DEDM): Revi...sushil Choudhary
Electrical discharge machining (EDM) has been
recognized as an efficient production method for precision
machining of electrically conducting hardened materials.
EDM in gaseous media is one of the fastest growing branches
among institutions involved in the research and development
of EDM as green manufacturing process Dry EDM is an
environmental friendly machining process were liquid
dielectric fluid is replaced by gaseous dielectric fluids. Present
& past performance of dry EDM process using various types
of gases & their mixtures as dielectric medium. The main
objective is to study the effect of pulse-on time, pulse-off time,
gap voltage, open voltage, servo voltage, discharge current;
polarity, pulse width, duty factor, gas or air pressure,
electrode rotation speed on Material removal Rate (MRR),
Surface Roughness (Ra) and Tool Wear Rate (TWR) also
discussed resulting finding condition for machining of
material depends on the optimization techniques or criteria.
Development of Dry EDM Technology enhance the
performance parameters such as material removal rate
(MRR), Low tool wear rate (TWR), thin recast layer.
A Literature Review On Dry Wire Electrical Discharge MachiningIJSRD
This document provides a literature review on dry wire electrical discharge machining (EDM). It summarizes several past studies that investigated dry EDM using various gases as dielectrics and how it improves performance over conventional EDM using liquid dielectrics. The review examines factors like material removal rate, surface finish, tool wear rate, and process parameters that influence these outputs. It discusses the basic working principles of dry wire EDM and evaluates the findings of multiple past studies on the effects of different machining variables in dry EDM.
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
1) A novel technique called double electrodes synchronous servo electrical discharge grinding (DESSEDG) is presented to machine non-conductive engineering ceramics with high efficiency and precision by integrating advantages of electrical discharge machining (EDM) and mechanical grinding.
2) In the DESSEDG process, a conductive grinding wheel rotates on the workpiece surface while a thin copper sheet electrode is automatically fed to the area where the wheel and workpiece meet, causing electrical discharges that erode the workpiece surface.
3) The eroded layer is then removed by the grinding wheel, combining the material removal of EDM with mechanical grinding for higher efficiency machining of hard non-conductive ceramics compared
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
This document is a project report submitted to Gujarat Technological University for their undergraduate program. It examines the experimental study of the effect of process parameters on the performance of electrical discharge machining (EDM). The project was conducted by four students under the guidance of a professor from the Mechanical Engineering department. The report includes certificates from the guide and examiners. It also acknowledges the help received. The abstract provides an overview of the focus of the project which is to analyze how current, voltage, pulse-on time and pulse-off time affect the material removal rate of the EDM process. The literature review covers past research conducted on improving the speed and accuracy of EDM as well as applying it to new materials.
This document provides a dissertation on investigating the machining characteristics of titanium alloy (Ti-6Al-4V) using the electrical discharge machining (EDM) process. The dissertation includes an introduction to traditional and non-traditional machining processes. It then focuses on EDM, including the history, types, principles, parameters, materials, advantages, and limitations. The methodology section describes the materials, equipment, experimental design using Taguchi methods, and parameters/levels studied. Results and discussions are presented on material removal rate, tool wear rate, surface roughness, and microhardness based on experiments. Finally, conclusions are drawn and scope for future work is discussed.
Study of process parameter of wire electric discharge machining the reviewIAEME Publication
This document summarizes the process parameters of wire electric discharge machining (WEDM). It discusses the key electrical parameters like pulse duration, pulse interval, servo voltage, and peak current. It also discusses the electrode wire parameters like wire size, material, tension and feed. Additionally, it covers dielectric fluid parameters and workpiece parameters that influence the WEDM process. The document provides details on how each parameter impacts material removal rate and machining characteristics.
The document is a project report submitted by four students to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The report investigates optimizing the wire electrical discharge machining (WEDM) process parameters using Taguchi methods and grey relational analysis. It includes sections on the introduction of WEDM, literature review, work undertaken including the experimental setup and design, results and discussion of optimizing material removal rate, surface roughness and electrode consumption, and conclusions. The goal is to determine the optimal process parameters to achieve higher machining rates with the desired accuracy and minimal surface damage using statistical analysis techniques.
Dynamic Monitoring Of Information in Large Scale Power GridsIJSRD
this document proposes the software model for detection and analysis of cascading faults in the operation of large scale power grids. Using data mining technologies, probable patterns can be detected for faults and proper mitigation measures can be taken. Firstly, the fault is detected by checking the stability of system. Then event sequences are calculated to best approximate the fault node. Then by analyzing the severity of vulnerability and region in which vulnerability would occur, proper ICT Technologies can make operators aware about the faults. Hence, speeding up the existing mechanisms. This model aims to solve problem of detection more efficiently than existing systems.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
This document summarizes a study that investigated the effect of process parameters on machining EN31 steel using electrical discharge machining (EDM). Experiments were conducted using different tool materials (copper, aluminum, and EN24), supply currents, flushing pressures, and pulse-on times. The experiments analyzed their influence on surface roughness, material removal rate, tool wear rate, and taper. The results of this study can help optimize the EDM process for machining EN31 steel.
Experimental Study of Static and Rotary Electrode on Electrical Discharge Mac...IRJET Journal
This document summarizes an experimental study on the effects of static and rotary graphite electrodes on electrical discharge machining (EDM). Experiments were conducted using a graphite electrode to machine copper-nickel alloy with both static and rotary electrodes. Material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) were analyzed at different discharge currents for both static and rotary electrodes. The results showed that MRR and TWR increased with increasing discharge current and were higher for the rotary electrode, while surface roughness was lower for the rotary electrode. In conclusion, a rotary graphite electrode provided better surface quality and higher MRR but also higher TWR compared to a static electrode.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
An Electrode Shape Configuration on the Performance of Die Sinking Electric D...IJERA Editor
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy
between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of
successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using
different electrode shapes has been carried out. This Research discusses the performance of die sinking EDM due to the
shape configuration of the electrode. The effect of electrode shapes configuration on the performance of die sinking electric
discharge machine has been carried out. The optimization of the parameters of the EDM machining has been carried out by
using the taguchi‟s method for design of experiments (DOE). In this research we have used taguchi‟s method for design of
experiments with three input parameters and their three levels of experiments. The dielectric used is kerosene diluted with
water. The objective of the analysis is to optimize the process parameters of EDM with the help of taguchi method and using
Minitab software.
Fluid Dynamic Simulation and Experimental Study of Honeycomb Seal Structures ...ijmech
Electrochemical discharge machining (ECDM) is a composite technology that combines electric discharge machining (EDM) with electrochemical machining (ECM). In this study, ECDM was used for the processing of honeycomb seal structures, and fluid dynamic simulation and experimental study were conducted. A vortex effect was observed, hindering the electrolyte flow. Compared to other fluid supply methods, a bilateral fluid supply can reduce vorticity and velocity, weakening the vortex effect. According to the result and the current signals after discrete wavelet transformation (DWT), the higher voltage and flow rate can increase total energy and exacerbate the vortex effect respectively, and strengthen the EDM and ECM effect, resulting in more processing depth, over corrosion depth, and molten product height. However, the higher electrolyte concentration can reduce the EDM effect, and enhance the ECM effect, which leads to more over corrosion depth, less processing depth and molten product height. The research results proved that ECDM has a good effect on processing honeycomb seal structures.
Optimizing Process Parameters on SR and MRR of Steel by EDMIRJET Journal
This document summarizes an experiment that optimized process parameters for electric discharge machining (EDM) of steel to improve material removal rate (MRR) and surface roughness (SR). Stainless steel 316 samples were machined using a copper electrode. A pilot study tested different levels of discharge current, pulse on-time, pulse off-time, and dielectric pressure. Graphs showed that MRR increased with higher current due to increased spark intensity and melting/vaporization, while SR also increased with higher current. MRR decreased with longer pulse on-time due to a wider plasma channel. Based on the pilot study, a Taguchi L18 design of experiments was used to further test current, pulse on-time,
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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MULTI OBJECTIVE OPTIMIZATION OF NEAR-DRY EDM PROCESS USING RESPONSE SURFACE M...IAEME Publication
The correct selection of manufacturing technique is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). It is capable of machining geometrically complex or hard
material components, which are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries.
Anaysis of Material Removal Rate of AISI 304 SS In EDM Processijsrd.com
EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is AISI 304 Stainless steel taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are current, pulse on time and duty cycle. Taguchi method is applied to create an L27 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR), Surface Roughness (SR) and Overcut (OC) is studied and investigated. The tool material is copper. The results obtained showed that current was the most significant parameter followed by pulse on time and the least significant was the duty cycle for the entire three responses namely Material removal rate, Surface roughness and overcut. With the increase in current and duty cycle MRR increased but for pulse on time it increased only up to 100 µs and then started to decrease. SR increased significantly with the increase in current; for pulse on time it increased up to 100 µs and after that there was no significant increase; and in case of duty cycle SR increased up to 70% and then started to decrease. OC increased with the increase in current and pulse on time but in different fashion and in case of duty cycle, OC increased up to 70% and then started decreasing.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
This document discusses analyzing process parameters in wire electrical discharge machining (WEDM) of Inconel 718, a nickel-based super alloy. The objectives are to investigate significant WEDM parameters that affect material removal rate, electrode wear ratio, and hardness; study the effect of parameters on dimensional output like circularity and cylindricity; establish optimal WEDM parameters for Inconel; and develop an empirical model using Taguchi's design of experiments. The document reviews literature on modeling and optimizing WEDM performance and discusses the mechanism and influencing parameters of the WEDM process.
Optimization of Process Parameters And Dielectric Fluids on Machining En 31 B...IJERA Editor
The electric discharge machining is the one of the most desirable machining process for the materials which are having high hardness and good thermal conductivity. The EDM process surpassed through the technological barriers by overcoming limitations like processing speed, material conductivity, dimensional accuracy, and surface finish and so on. However, environmental impact due to release of toxic emissions aerosols during the process, poor operational safety due to fire hazard, electromagnetic radiation and non-bio degradable waste are the major problems concerned with conventional dielectric fluids (i.e. kerosene, hydro carbon, etc.,). To reduce the problems with conventional die electric fluids waste palm oil blended with kerosene is used. The process is mostly used in situations where intricate, complex shapes need to be machined in very hard materials. The objective of this work is to study the influence of four design factors current (I), voltage (V), pulse on(P on), and pulse off(P off) which are the most relevant parameters to be controlled by the EDM process over machining characteristics such as material removal rate (MRR) characteristics of surface integrity such as average surface roughness (Ra). Multi Objective optimization of process parameters is done by using TOPSIS
effect of electrode material and geometry on edm performance for ohns dies s...INFOGAIN PUBLICATION
Modern EDM machinery is capable of machining micro-hole, thin slots, geometrically complex or hard material components, that are precise and difficult to machine, such as heat treated tool steels, composites, super alloys, etc. The studies of an experimental investigation evaluate the effects of EDM machining parameters such as MRR, EWR and Surface Roughness with two different electrode materials. The process parameters such as Input current, Pulse on time and duty cycle keeping flushing pressure constant. The full factorial design of experiment (L25) is used to study the effects of machining parameters. Investigations indicate that the output parameters of EDM increases with the increase in input current and the best machining rates are achieved with copper with through hole electrodes, better surface roughness compare to brass electrode. A brass electrode with higher input current and maximum pulse on time resulted in more EWR compared to copper electrodes. Also the increase in MRR by copper electrode, it improves the SR during Electric Discharge Machining.
IRJET- Investigation of Nickel Aluminium Alloy by Electric Discharge Machine,...IRJET Journal
This document reviews research on electric discharge machining (EDM) of nickel aluminum composites. It discusses how nickel aluminum composites were manufactured using sand casting. It then summarizes the methodology, parameters studied, and experiments conducted to investigate the effects of EDM process parameters like discharge current, pulse on/off time, and voltage gap on material removal rate, tool wear, and surface roughness when machining nickel aluminum composites. The document concludes that adding powder to the dielectric fluid can improve material removal rate and reduce surface roughness compared to conventional EDM without additives.
Trends in Wire Electrical Discharge Machining (WEDM): A ReviewIJERA Editor
This document summarizes research on trends in wire electrical discharge machining (WEDM). It reviews several studies that investigated how WEDM process parameters affect outcomes like surface roughness, cutting speed, and material removal rate. Different materials were examined, including metals, composites, and silicon. Process parameters like pulse on-time, current, wire feed rate, and dielectric fluid composition were found to influence the results. Statistical methods like Taguchi experiments and analysis of variance were commonly used to determine significant factors and optimize the process.
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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In today’s emerging world of Internet, each and every thing is supposed to be in connected mode with the help of billions of smart devices. By connecting all the devises used in our day to day life, make our life trouble less and easy. We are incorporated in a world where we are used to have smart phones, smart cars, smart gadgets, smart homes and smart cities. Different institutes and researchers are working for creating a smart world for us but real question which we need to emphasis on is how to make dumb devises talk with uncommon hardware and communication technology. For the same what kind of mechanism to use with various protocols and less human interaction. The purpose is to provide the key area for application of IoT and a platform on which various devices having different mechanism and protocols can communicate with an integrated architecture.
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In recent years usage of private vehicles create urban traffic more and more crowded. As result traffic becomes one of the important problems in big cities in all over the world. Some of the traffic concerns are traffic jam and accidents which have caused a huge waste of time, more fuel consumption and more pollution. Time is very important parameter in routine life. The main problem faced by the people is real time routing. Our solution Virtual Eye will provide the current updates as in the real time scenario of the specific route. This research paper presents smart traffic navigation system, based on Internet of Things, which is featured by low cost, high compatibility, easy to upgrade, to replace traditional traffic management system and the proposed system can improve road traffic tremendously.
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Use PyCharm for remote debugging of WSL on a Windo cf5c162d672e4e58b4dde5d797...shadow0702a
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The guide then proceeds to explain how to set up the SSH service within the WSL environment, an integral part of the process. Alongside this, it also provides detailed instructions on how to modify the inbound rules of the Windows firewall to facilitate the process, ensuring that there are no connectivity issues that could potentially hinder the debugging process.
The document further emphasizes on the importance of checking the connection between the Windows and WSL environments, providing instructions on how to ensure that the connection is optimal and ready for remote debugging.
It also offers an in-depth guide on how to configure the WSL interpreter and files within the PyCharm environment. This is essential for ensuring that the debugging process is set up correctly and that the program can be run effectively within the WSL terminal.
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Software Engineering and Project Management - Software Testing + Agile Method...Prakhyath Rai
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A Review on optimization of Dry Electro Discharge Machining Process Parameters
1. IJSRD - International Journal for Scientific Research & Development| Vol. 1, Issue 9, 2013 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 1901
Abstract—Dry EDM is an environmental friendly machining
process were liquid dielectric is replaced by gaseous
dielectrics. There are presented performance characteristics
of the process, using various gases and their mixtures as
dielectric medium. The main aim is to study the effect of
gap voltage, discharge current, pulse-on time, duty factor,
air pressure and spindle speed on Material removal Rate
(MRR), Surface Roughness (Ra) and Tool Wear Rate
(TWR). Influence of gas pressure, flow rate and rotational
speed of the electrode are also discussed resulting in finding
optimal conditions for machining, depending on the
optimization criteria.
Key words: Dry EDM, MRR, Ra, TWR
I. INTRODUCTION
Electric discharge machining (EDM) is one of the most
popular non-traditional machining processes being used
today. Use of mineral oil-based dielectric liquids is the
major cause of environmental concerns associated with the
EDM process. Dry EDM is an environment-friendly
modification of the oil EDM process in which the liquid
dielectric is replaced by a gaseous medium. Dielectric
wastes generated during the oil EDM process are very toxic
and cannot be recycled. Also, toxic fumes are generated
during machining due to high temperature chemical
breakdown of mineral oils. The use of oil as the dielectric
fluid also makes it necessary to take extra precaution to
prevent fire hazards. Replacing liquid dielectric by gases is
an emerging field in the environment-friendly EDM
technology. High velocity gas flowing through the tool
electrode into the inter-electrode gap substitutes the liquid
dielectric. The flow of high velocity gas into the gap
facilitates removal of debris and prevents excessive heating
of the tool and work piece at the discharge spots. Providing
rotation or planetary motion to the tool has been found to be
essential for maintaining the stability of the dry EDM
process. Tubular tools are used and as the tool rotates, high
velocity gas is supplied through it in to the discharge gap.
Tool rotation during machining not only improves the
process stability by reducing arcing between the electrodes
but also facilitates in the flushing of debris. The first
reference to dry EDM can be found in a 1985 NASA
Technical report [1]. It was briefly reported that argon and
helium gas were used as dielectric medium to drill holes
using tubular copper electrode. Further details are however
not available. Later in 1991, Kunieda et al. showed that
introducing oxygen gas into the discharge gap improves the
material removal rate (MRR) in a water-based dielectric
medium. It was in 1997 that the feasibility of using air as the
dielectric medium was first demonstrated by Kunieda et al.
High velocity gas jet through a thin walled tubular electrode
was used as dielectric. Further research in this field has
brought out some of the essential features of the process. It
is now known that some of the advantages of the dry EDM
process are: low tool wear, lower discharge gap, lower
residual stresses, smaller white layer and smaller heat
affected zone. Also, several studies have been made to
improve the performance of the process such as by using a
piezoelectric gap control mechanism and by introducing
ultrasonic vibrations to the work piece. Dry EDM has also
been successfully implemented in wire EDM operations.
Tao et al. have recently reported that oxygen gas and copper
tool combination leads to a high MRR in dry EDM and
nitrogen gas water mixture dielectric and graphite tool
combination leads to high surface finish in near- dry EDM.
However, the current literature in the field is insufficient.
II. WORKING PRINCIPLE OF DRY EDM
Dry Electric Discharge Machining (Dry EDM) is a
modification of the oil EDM process in which the liquid
dielectric is replaced by a gaseous dielectric. High velocity
gas flowing through the tool electrode into the inter-
electrode gap substitutes the liquid dielectric. The flow of
high velocity gas into the gap facilitates removal of debris
and prevents excessive heating of the tool and work piece at
the discharge spots. Providing rotation or planetary motion
to the tool has been found to be essential for maintaining the
stability of the dry EDM process. The dry EDM process
schematic is shown in Figure 1.
Fig. 1: Schematic of dry EDM process
Tubular tools are used and as the tool rotates, high velocity
gas is supplied through it into the discharge gap. Gas in the
gap plays the role of the dielectric medium required for
electric discharge. Also, continuous flow of fresh gas into
the gap forces debris particles away from the gap. Tool
rotation during machining not only facilitates flushing but
A Review on optimization of Dry Electro Discharge Machining Process
Parameters
Prof. Chirag P. Patel1
Kashyap R. Modi2
Dr. M. G. Bhatt3
1, 3
Associate Professor 2
P. G. Student (M. Tech. - AMT)
1, 2, 3
Mechanical Engineering Department
1, 2
UVPCE, Ganpat University, Kherva 3
GEC, Bhavnagar.
2. A Review on optimization of Dry Electro Discharge Machining Process Parameters
(IJSRD/Vol. 1/Issue 9/2013/0052)
All rights reserved by www.ijsrd.com 1902
also improves the process stability by reducing arcing
between the electrodes.
III. LITERATURE REVIEW
The first reference to dry EDM can be found in a 1985
NASA Technical report [1]. It is briefly reported that argon
and helium gas were used as dielectric medium to drill holes
using tubular copper electrode. Further details are not
available.
Later in 1991, Kunieda et. al. [2] showed that
introducing oxygen gas into the discharge gap improves
MRR in a water based dielectric medium. Later in 1997, that
the feasibility of using air as the dielectric medium was first
demonstrated by Kunieda et al. [3]. High velocity gas jet
through a thin walled tubular electrode was used to serve the
purpose of a dielectric.
Yu et. al. [4] demonstrated the effectiveness of the
dry EDM method in machining of cemented carbide. Dry
EDM was used for groove milling and three- dimensional
milling. Copper-tungsten tubes were used as tool electrodes
and high velocity oxygen gas was used as the dielectric. Dry
EDM performance was compared to oil die sinking EDM
and oil EDM milling. It was found that dry EDM milling
produces the smallest form deviation due to very low tool
wear ratio. The machining speed in dry EDM is higher than
for oil milling EDM but lower than oil die-sinking EDM.
However, it was argued that the total time required for
making multiple electrodes in die-sinking EDM puts it at a
disadvantage to dry EDM milling. Fewer tool electrodes are
required in dry EDM due to lower tool wear. The total
machining time for dry EDM may then be lower than die-
sinking EDM.
Q.H. Zhang, R. Du, J.H. Zhang, Q.B. Zhang et. al.
[5] studies that an investigation of ultrasonic-assisted
electrical discharge machining in gas. In the process of
UEDM in gas, the tool electrode is a thin-walled pipe, the
high-pressure gas medium is applied from inside, and the
ultrasonic actuation is applied onto the work piece. In
experiment, the work piece material is AISI 1045 steel and
the electrode material is copper. The experiment results
indicate that (a) the Material Removal Rate (MRR) is
increased with respect to the increase of the open voltage,
the pulse duration, the amplitude of ultrasonic actuation, the
discharge current, and the decrease of the wall thickness of
electrode pipe; and (b) the surface roughness is increased
with respect to the increase of the open voltage, the pulse
duration, and the discharge current. Based on experimental
results, a theoretical model to estimate the MRR and the
surface roughness is developed. UEDM in gas is a useful
process. Its material removal rate (MRR) is nearly twice as
much as EDM in gas, though is less than that of
conventional EDM. UEDM in gas is affected by at least five
factors: open voltage, discharge current, discharge duration,
the wall thickness of the pipe electrode, and the amplitude of
the ultrasonic actuation. Among these factors, the discharge
current and the pulse duration are the most significant.
Though, the wall thickness of the pipe electrode is also
important, as it affects removal of molten work piece
material. In the process of UEDM in gas, the increase of
MRR is at the expense of surface roughness.
S. K. Saha and S. K. Choudhury et.al [6] studied
parametric Analysis of the process has been performed with
tubular copper tool electrode and mild steel work piece.
Experiments have been conducted using air as the dielectric
medium to study the effect of gap voltage, discharge current,
pulse-on time, duty factor, air pressure and spindle speed on
material removal rate (MRR), surface roughness (Ra) and
tool wear rate (TWR). First, a set of exploratory experiments
has been performed to identify the optimum tool design and
to select input parameters and their levels for later stage
experiments. Empirical models for MRR, Ra and TWR have
then been developed by performing a designed experiment
based on the central composite design of experiments.
Response surface analysis has been done using the
developed models. Analysis of variance (ANOVA) tests
were performed to identify the significant parameters.
Current, duty factor, air pressure and spindle speed were
found to have significant effects on MRR and Ra. However,
TWR was found to be very small and independent of the
input parameters. Flow characteristic of air in the inter-
electrode gap affects the MRR and the surface roughness
(Ra). There exists an optimum number of air-flow holes (in
the tool) for which the MRR is highest and the Ra is lowest.
From the designed set of experiments based on CCD it was
found that discharge current, duty factor, air pressure and
spindle speed are the significant factors which affect MRR
and MRR increases with an increase in any of these factors.
From CCD experiments it was found that except for gap
voltage all other input parameters (discharge current, pulse-
on time, duty factor, air pressure and spindle speed) have
significant effect on Ra. Ra values decrease with a decrease
in the values of current and duty factor. Also, Ra values
decrease with an increase in the values of air pressure and
spindle speed.
Grzegorz Skrabalak, Jerzy Kozak et. al. [7] studies
on Dry Electrical Discharge Machining results of simulation
and mathematical modelling of the material removal rate of
electro discharge milling process with compressed air as
dielectric. There are also presented basic characteristic of
the DEDM milling process and comparison of this green
machining method with kerosene based EDM milling. Fig.2
shows Material removal rate comparison of EDM in
kerosene and Dry EDM. Fig.3 shows Comparison of
TWR/MRR coefficient for kerosene and dry EDM milling
Fig. 2: Material removal rate comparison
3. A Review on optimization of Dry Electro Discharge Machining Process Parameters
(IJSRD/Vol. 1/Issue 9/2013/0052)
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Fig. 3: Comparison of TWR/MRR coefficient for
kerosene and dry EDM milling
The method is useful not only when thin-walled electrodes
are used, like during tests run in Japan, but also when the
active area of the electrode is relatively big (in comparison
to the gas supply channels) – more than 50%. DEDM
milling process may be very useful especially for micro
machining. Due to the tool wear ratio it is more precise than
EDM milling in kerosene, what is important aspect in case
of machining in micro-scale. Also process of preparing tool
paths is much easier, as the tool wear is negligible.
Yusliza Yusoff, Mohd Saliin Ngadiman, Azlan Mohd Zain
et. al. [8] studied an overview on NSGA-II optimization
techniques of machining process parameters. NSGA-II is a
well-known, fast sorting and elite multi objective genetic
algorithm. Process parameters such as cutting speed, feed
rate, rotational speed etc. are the considerable conditions in
order to optimize the machining operations in minimizing or
maximizing the machining performances. Unlike the single
objective optimization technique, NSGA-II simultaneously
optimizes each objective without being dominated by any
other solution. NSGA-II as part of MoGA is a popular and
reliable technique that can be used in optimizing the process
parameters of multiple machining performances. It can be
observed that; (i) ANN, GP, fuzzy, regression analysis are
some of the methods used in modeling the machining
performance prediction, (ii) NSGA-II is a multi-objective
optimization tool that can meet the requirements of the
machining process in finding set of solutions based on
combination of suitable variables.
R. Rajesh and M. Dev Anand et. al. [9] studied on The
Optimization of the Electro-Discharge Machining Process
Using Response Surface Methodology and Genetic
Algorithms. A proper selection of machining parameters for
the EDM process is dependent on operator’s technologies
and experience because of numerous and diverge range.
Machining parameters provided by machine tool builder
cannot meet operator’s requirement. To solve this task,
multiple regression model and modified Genetic Algorithm
model are developed as efficient approaches to determine
the optimal machining parameters in electric discharge
machine. In this paper working current, working voltage, oil
pressure, spark gap, Pulse On Time and Pulse Off Time on
Material Removal Rate (MRR) and Surface Finish (Ra) has
been studied. Empirical models for MRR and Ra have been
developed by conducting a designed experiment based on
the Grey Relational Analysis. Genetic Algorithm (GA)
based multi-objective optimization for maximization of
MRR and minimization of Ra has been done by using the
developed empirical models. Metal removal rate and surface
roughness are combined to have a single objective as grey
relational grade by the application of grey relational
analysis. Linear regression model have been developed to
map the relationship between machining parameters and
output responses. Finally the optimal conditions obtained by
GA as. i.e., current at 3 A, voltage at 78 V, gap at 0.35, flow
rate at 1, pulse ON as 1 and pulse OFF as 8 for maximizing
MRR and minimize the surface roughness simultaneously
among the experimental data.
Ramezan Ali Mahdavi Nejad et. al. [10] studied
that Silicon Carbide (SiC) machining by traditional methods
with regards to its high hardness is not possible. Electro
Discharge Machining, among non-traditional machining
methods, is used for machining of SiC. The present work is
aimed to optimize the surface roughness and material
removal rate of electro discharge machining of SiC
parameters simultaneously. As the output parameters are
conflicting in nature, so there is no single combination of
machining parameters, which provides the best machining
performance. Artificial neural network (ANN) with back
propagation algorithm is used to model the process. A multi-
objective optimization method, non-dominating sorting
genetic algorithm-II is used to optimize the process. Effects
of three important input parameters of process viz.,
discharge current, pulse on time (Ton), pulse off time (Toff)
on electric discharge machining of SiC are considered.
Experiments have been conducted over a wide range of
considered input parameters for training and verification of
the model. A Pareto-optimal set has been predicted in this
work. Various ANN architectures have been studied, and 3-
5-5-2 is selected. Material removal rate and surface
roughness have been optimized as objectives by using a
multi-objective optimization method. Non-dominating
sorting genetic algorithm-II and finally Pareto-optimal sets
of material removal rate and surface roughness are obtained.
IV. CONCLUSION
1) Fewer tool electrodes are required in dry EDM due to
lower tool wear. The total machining time for dry EDM
may then be lower than die-sinking EDM.
2) In the process of UEDM in gas, the increase of MRR is
at the expense of surface roughness.
3) It was found that discharge current, duty factor, air
pressure and spindle speed are the significant factors
which affect MRR and MRR increases with an increase
in any of these factors. Ra values decrease with an
increase in the values of air pressure and spindle speed.
4) NSGA-II is a multi-objective optimization tool that can
meet the requirements of the machining process in
finding set of solutions based on combination of suitable
variables.
5) Genetic Algorithm (GA) based multi-objective
optimization for maximization of MRR and
minimization of Ra has been done by using the
developed empirical models.
6) Material removal rate and surface roughness have been
optimized as objectives by using a multi-objective
optimization method.
4. A Review on optimization of Dry Electro Discharge Machining Process Parameters
(IJSRD/Vol. 1/Issue 9/2013/0052)
All rights reserved by www.ijsrd.com 1904
V. FUTURE SCOPE
For Dry EDM Ceramic materials both conductive and
nonconductive materials not so much work is carried out.
So, for future we can consider this material for research
work in Dry EDM. For analysis and optimization we can use
soft computing techniques like GA, Fuzzy Logic, and ANN
are carried out.
REFERENCES
[1] Ramani, V., Cassidenti, M. L., Inert-Gas Electrical
Discharge Machining (1985) NASA, National
Technology Transfer Center (NTTC), Wheeling, WV.
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Improvement of EDM efficiency by supplying
oxygen gas into gap (1991) CIRP Annals-
Manufacturing Technology 40, pp. 215-218.
[3] M. Kunieda, M. Yoshida and N. Taniguchi, Electrical
discharge machining in gas, (1997) CIRP Annals-
Manufacturing Technology 46, pp. 143-146.
[4] Yu, Z., T. Jun, and K. Masanori, Dry electrical
discharge machining of cemented carbide (2004)
Journal of Materials Processing Technology, 14th
International Symposium on Electro machining (ISEM
XIV) 149 (1-3) pp. 353-357.
[5] Zhang, Q.H., Du, R., Zhang, J.H., Zhang, Q.B. An
investigation of ultrasonic assisted electrical discharge
machining in gas (2006) International Journal of
Machine Tools and Manufacture 46 (12-13), pp. 1582-
1588.
[6] S.K.Saha and S.K.Chaudhary, Experimental
investigation and empirical modeling of the dry
electric discharge machining process, International
Journal of Machine Tools & Manufacture 49 (2009)
297–308.
[7] Grzegorz Skrabalak, Jerzy Kozak, Study on Dry
Electrical Discharge Machining, Proceedings of the
World Congress on Engineering 2010 Vol III WCE
2010, London, U.K.
[8] Yusliza Yusoff, Mohd Salihin Ngadiman, Azlan Mohd
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Process Parameters, Procedia Engineering 15 ( 2011 )
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[9] R.Rajesh and M. Dev Anand, The Optimization of the
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International Conference on Modelling, Optimization
and Computing (ICMOC - 2012), Procedia
Engineering 38( 2012 ) 3941 – 3950.
[10] Ramezan Ali MahdaviNejad, Modeling and
Optimization of Electrical Discharge Machining of SiC
Parameters, Using Neural Network and Non-
dominating Sorting Genetic Algorithm (NSGA II),
Materials Sciences and Applications, 2011, 2, 669-675