Electrical discharge machining (EDM) process is one of the most commonly used nonconventional
precise material removal processes. Electrical discharge machining (EDM) is a process for
shaping hard metals and forming deep complex shaped holes by arc erosion in all kinds of electroconductive
materials. Erosion pulse discharge occurs in a small gap between the work piece and the
electrode. This removes the unwanted material from the parent metal through melting and vaporizing in
presence of dielectric fluid. In recent years, EDM researchers have explored a number of ways to improve
EDM Process parameters such as Electrical parameters, Non-Electrical Parameters, tool Electrode based
parameters & Powder based parameters. This new research shares the same objectives of achieving more
efficient metal removal rate reduction in tool wear and improved surface quality. This paper reviews the
research work carried out from the inception to the development of die-sinking EDM, Water in EDM, dry
EDM, and Powder mixed electric Discharge Machining. Within the past decade. & also briefly describing the Current Research technique Trend in EDM, future EDM research direction.
Electrical discharge machining is basically a non-conventional material removal process which is widely used to produce dies, punches and moulds, finishing parts for aerospace and automotive industry, and surgical components. This process can be successfully employed to machine electrically conductive parts irrespective of their hardness, shape and toughness.
Review Study and Importance of Micro Electric Discharge Machiningsushil Choudhary
Micro EDM process is one of the micro- machining processes. It can be used to machine micro features and
makes a micro parts. There is a huge demand in the production of microstructures by a non-traditional method
which known as Micro-EDM. Micro-EDM process is based on the thermoelectric energy between the workpiece
and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of
50 μm -100 μm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with
various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges
occur in a small gap between the work piece and the electrode and at the same time removes the unwanted
material from the parent metal through the process of melting and vaporization. This paper describes the
importance, parameters, principle, difference between Macro and micro EDM, applications and advantages of μ-
EDM and discuss about the literature reviews based on performance measure in micro- EDMP process.
Experimental Investigation of Electrode Wear in Die-Sinking EDM on Different ...IJMER
EDM is an advanced machining method for manufacturing, hard material parts which
are difficult to machine by conventional machining process. There are various type of products which
can be produced by using Die-sinking EDM, such as dies, moulds. Parts of aerospace, automobile
industry and surgical components can be finished machined by EDM. In present scenario numbers of
researchers have explored a number of ways to improve EDM efficiency. The optimum selection of
manufacturing condition is very important in manufacturing processes as they determine surface
quality, dimensional accuracy of the obtained parts. This experimental investigation is mainly focused
on electrode wear in cylindrical copper electrode on different pulse-on & off time (µs) at constant
current(amp.) which is an important parameter. In this experimental work, an investigation has been
made to optimize the response parameter (electrode wear) of EDM on die-steel with electrolytic
cylindrical copper electrode. Die-steel (HRC-58) is widely used in production of dies. In this
investigation copper has been taken as electrode and die-steel as a work piece. Electrode wear has
been investigated in the form of weight (gm) and length (mm.) of electrode on different input process
parameters. viz constant discharge current (amp.), pulse on time (T-on), pulse off time (T-off)
Electrical discharge machining is basically a non-conventional material removal process which is widely used to produce dies, punches and moulds, finishing parts for aerospace and automotive industry, and surgical components. This process can be successfully employed to machine electrically conductive parts irrespective of their hardness, shape and toughness.
Review Study and Importance of Micro Electric Discharge Machiningsushil Choudhary
Micro EDM process is one of the micro- machining processes. It can be used to machine micro features and
makes a micro parts. There is a huge demand in the production of microstructures by a non-traditional method
which known as Micro-EDM. Micro-EDM process is based on the thermoelectric energy between the workpiece
and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of
50 μm -100 μm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with
various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges
occur in a small gap between the work piece and the electrode and at the same time removes the unwanted
material from the parent metal through the process of melting and vaporization. This paper describes the
importance, parameters, principle, difference between Macro and micro EDM, applications and advantages of μ-
EDM and discuss about the literature reviews based on performance measure in micro- EDMP process.
Experimental Investigation of Electrode Wear in Die-Sinking EDM on Different ...IJMER
EDM is an advanced machining method for manufacturing, hard material parts which
are difficult to machine by conventional machining process. There are various type of products which
can be produced by using Die-sinking EDM, such as dies, moulds. Parts of aerospace, automobile
industry and surgical components can be finished machined by EDM. In present scenario numbers of
researchers have explored a number of ways to improve EDM efficiency. The optimum selection of
manufacturing condition is very important in manufacturing processes as they determine surface
quality, dimensional accuracy of the obtained parts. This experimental investigation is mainly focused
on electrode wear in cylindrical copper electrode on different pulse-on & off time (µs) at constant
current(amp.) which is an important parameter. In this experimental work, an investigation has been
made to optimize the response parameter (electrode wear) of EDM on die-steel with electrolytic
cylindrical copper electrode. Die-steel (HRC-58) is widely used in production of dies. In this
investigation copper has been taken as electrode and die-steel as a work piece. Electrode wear has
been investigated in the form of weight (gm) and length (mm.) of electrode on different input process
parameters. viz constant discharge current (amp.), pulse on time (T-on), pulse off time (T-off)
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
Electrical Discharge Machining (EDM) is a non
conventional machining process which can be used to
machine electrically conductive work piece. The
electric discharge machine provides an effective
solution for machining hard conductive materials and
reproducing complex shapes. EDM involves the
phenomena such as: spark initiation, dielectric
breakdown, and thermo-mechanical erosion of metals.
High cost of non conventional machine tools,
compared to conventional machining, Optimization is
one of the techniques used in manufacturing process
area to arrive for the best manufacturing conditions,
which is an essential need for industries towards
manufacturing of quality products at lower cost. In
this paper various optimization technique such as
Taguchi method, artificial neural network (ANN),
Genetic Algorithms (GA), grey relational analysis
(GRA), Response Surface Methodology (RSM) used
in the field of electric discharge machining process.
The main objectives of optimization are to (i)
maximize the material removal rate (MRR), (ii)
minimize the surface roughness value and (iii)
maximize the tool wear ratio.
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
Electrical Discharge Machining (EDM) is a non
conventional machining process which can be used to
machine electrically conductive work piece. The
electric discharge machine provides an effective
solution for machining hard conductive materials and
reproducing complex shapes. EDM involves the
phenomena such as: spark initiation, dielectric
breakdown, and thermo-mechanical erosion of metals.
High cost of non conventional machine tools,
compared to conventional machining, Optimization is
one of the techniques used in manufacturing process
area to arrive for the best manufacturing conditions,
which is an essential need for industries towards
manufacturing of quality products at lower cost. In
this paper various optimization technique such as
Taguchi method, artificial neural network (ANN),
Genetic Algorithms (GA), grey relational analysis
(GRA), Response Surface Methodology (RSM) used
in the field of electric discharge machining process.
The main objectives of optimization are to (i)
maximize the material removal rate (MRR), (ii)
minimize the surface roughness value and (iii)
maximize the tool wear ratio.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Electrical Discharge Machine is an advanced machining method which removes metal by a series of recurring electrical discharges betweenn an electrode and a conductive workpiece, submerged in a dielectric fluid.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
Spot welding /certified fixed orthodontic courses by Indian dental academy Indian dental academy
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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.
Thermal analysis of various duct cross sections using altair hyperworks softwaresushil Choudhary
In this work thermal analysis and comparison of various duct cross sections is done computationally using Altair
Hyperworks Software. Simple Analytical results were obtained for conduction and convection through the ducts
which can be used to build up thermal circuit. The inner surface of all ducts is maintained at constant
temperature and ambient air is at certain temperature that is less than inner surface temperature of pipe. Due to
temperature difference heat will flow from higher temperature to lower temperature. Due to temperature
difference heat will flow from higher temperature to lower temperature. The material of pipe provides
conductive resistance and air provides convective resistance. Hence this is a mix mode of heat transfer. The heat
transfer takes place in one dimension only and properties are considered to be isotropic. The ducts are assumed
to be made of aluminium having known thermal conductivity and density. The surroundings of ducts have
known convective heat transfer coefficient and temperature. The results are obtained on hyperview which are for
heat flux, temperature gradient and grid temperature. The different characteristics can be obtained by varying the
material of the ducts.
Design and fabrication of dual chargeable bicyclesushil Choudhary
With the increase in fuel prices, pollution content in atmosphere and due to gradual end of the non renewable sources
of energy we have to alter the source of our energy in our vehicles. Considering all these reasons we have to switch
over to other sources of energy instead of using conventional sources such as petrol which in future will be going to
extinct. One way to alter the energy source is to go for electric vehicles or e bikes. Electric driven vehicles uses
battery as a source of energy which provide power to motor which in turn provide torque to wheels .The old design
of electric bicycle was having only a single mode of charging, it was just capable to travel 15 km through battery and
was not ergonomically good. The new design uses a low rpm alternator for charging the battery by keeping it in
contact with front wheel .A Motor of 0.5hp provides torque to the rear wheel and the gear ratio is kept 5:2 .battery
discharging time is approximately 2 hrs and charging time through alternator is 1 hour and the bicycle can attain a
maximum speed of 15 km/hr. This work is more beneficial in hilly region and confined areas like college campus
and schools, generating zero pollution, zero noise effect and no fuel consumption.
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.
The energy of sea waves can be absorbed by wave energy converters in a variety of manners, but in every case
the transferred power is highly fluctuating in several time-scales, especially the wave-to-wave or the wave group
time-scales. In most devices developed or considered so far, the final product is electrical energy to be supplied
to a grid. This paper discusses the use of sea wave energy with the help of oscillating column. The mechanism
converts the wave energy in to electrical power by converting the oscillating motion of waves in to rotary
motion. Using compression ring we can store the power produced by the impact. This stored energy can be
utilized in other strokes. The sea, which covers three quarters of the world’s surface, has been little utilized to
meet the peoples’ energy needs.
Role of Cloud Computing Technology in Agriculture Fieldssushil Choudhary
Use of Cloud computing technology in agricultural areas has greater chance in the overall development of India.
An effective implementation of cloud computing is encouraging in agricultural sector. Cloud Computing is
emerging today as a commercial infrastructure that eliminates the need for maintaining expensive computing
hardware, software, Information technology, staff, infrastructure, recourses and their maintenance. Cloud
computing is a network-based environment that focuses on sharing computations, Cloud computing networks
access to a shared pool of configurable networks, servers, storage, service, applications & other important
computing resources. In modern era of cloud computing technology very helpful for centralized the allagricultural
related data bank (Soil-related, weather, Research, Crop, Farmers, Agriculture marketing, fertilizers
and pesticide information) in the cloud. In this paper, also discuss Computing model, characteristics,
deployment model, cloud service model, cloud benefits and challenge of cloud computing in agriculture field.
Design and fabrication of variable steering ratio mechanism for light Motor v...sushil Choudhary
To facilitate easy and proper steering of the vehicle while negotiating a turn, as per the requirements of driver in
different situations like hair pin bends in hilly regions, sudden turns in highways and city streets or in sports car
during race events an improved steering system is needed to address these problems. The steering arrangement
used in a normal automobile was investigated and to solve the above problems a variable steering ratio
mechanism was designed and fabricated, with the aim to determine if incorporation of variable steering ratio
mechanism will make an improvement in the steady and transient state handling of the automobile. The size of
the pinion gear and the number of teeth on the gear determine the rack-and-pinion steering ratio. The steering
wheel must be turned one revolution to turn the front wheels one sixteenth of a turn, the steering ratio is 1 to
1/16. Reversing the numbers gives a ratio of 16 to 1, or 16:1. This steering ratio is always fixed. A variable
steering ratio mechanism was fabricated by using constant mesh type gears from Bajaj-Super and steering
mechanism from Tata-Nano. Gear housing using wood is created and gear shifting arrangement incorporated. It
was observed that on engaging the 1st gear steering ratio is increased to 9.92:1. On engaging the 2nd gear
steering ratio is increased to 7.20:1, On engaging the 3rd gear steering ratio is increased to 4.96:1 On engaging
the 4th gear steering ratio is increased to 3.52:1. The effort required for steering is increased due to these ratios
as energy is lost due to friction. This mechanism can only be practical if used in conjugation with power assist.
Cloth washing is one of the essential parts of the life but it is considered undesirable because of the involvement
of efforts, time, energy and cost. Nowadays a wide variety of washing machines are available in the market and
there is a tough competence among the manufacturers. The cost of washing machine varying from Rs.10,000 to
1,50,000 depending upon features and capabilities. Very costly washing machines are equipped with facility of
dry cleaning too. All of the washing machines available in the market are electric power driven and basic
principle of their operation depends upon creation of the turbulent flow of detergent around the dirty clothes.
Drying of the clothes is based upon rotation of wet clothes at very high rpm so that water droplets can be
separated out due to centrifugal action. In our country where approximately 70% population is living with very
poor economic status, those people cannot have a washing machine because of cost constraints and
unavailability of electricity due to any reason. The present work is an attempt to develop a concept to make a
cloth washing mechanism which can meet out the requirements of above mentioned 70% population of the
nation. Working principle of this concept is no more different from available similar type of machine with a
difference driving mechanism of the machine. The objective of bringing down the initial cost and operating cost
of washing machine is almost achieved in present work within the limitation of work as mentioned.
Fabrication and Study of Mechanical Properties of Bamboo Fibre Reinforced Bio...sushil Choudhary
In the present work experimental investigation has been carried out to study the effect of bamboo fibres at
different weight percentages (20, 30 and 40) to modify epoxy resin. Tests are conducted on 100 kN servohydraulic
universal testing machine under displacement mode of control, digital Rockwell hardness testing
machine and impact testing machine. Modifying epoxy resin through bamboo fibres and improve mechanical
properties is main focus of this study. Bamboo fibres at different wt% (20, 30 and 40) are filled in epoxy resin
and the effects of mixing bamboo fibres on mechanical and physical properties are studied. On the basis of
mechanical testing results it is found that 30 wt% of bamboo fibre mixed epoxy is giving optimum mechanical
properties. The addition of bamboo fibres has improved tensile, flexural and impact properties of epoxy resin
and increased water absorption of the material. On the basis of overall study the epoxy modified with 30% of
bamboo fibre is found to be better than other combinations.
Electronic Head Lamp Glare Management System for Automobile Applicationssushil Choudhary
Headlamp glare is an issue that has grown in terms of public awareness over the past decade.
High beam of headlight of an on-coming car has blinding effect and decreases visibility during night
driving dangerously. The drivers of most vehicles use high, bright beam while driving at night. This causes
a discomfort to the person traveling from the opposite direction. He experiences a sudden glare for a short
period of time. This is caused due to the high intense headlight beam from the other vehicle coming
towards him from the opposite direction. We are expected to dim the headlight to avoid this glare. This
glare causes a temporary blindness to a person resulting in road accidents during the night. This model
concept eliminates the requirement of manual switch by the driver which is not done at all time. This
concept very useful in the automobile field applications, which provides safety of driver during night
driving. The construction, working, advantages & future scope of the system is discussed detail in this
paper.
Identification of Critical Issues and Solutions during ERP Software Developme...sushil Choudhary
Information technology is revolutionizing the way the business intelligence is being done. For any organization to succeed, all business unit or departments should work in harmony towards a common goal. ERP is a very powerful tool, which provides perfect information system to maintain the various functional business modules of an enterprise. Most organization is turning to available ERP software package for solution to their information management problem. ERP package if chosen correctly, implemented sensibly and used capably will enhance the output and profit of the any association considerably. ERP software package is at the cutting frame of information system technology. ERP software package help to manage institute and firm extensive business processes, using a common database and shared management reporting tool. ERP software supports the well-organized operation of business actions, including sales, marketing, manufacturing, accounting and staffing. The aim of this study is to provide a contribution to the research field of the ERP software development life cycle (SDLC), critical success factors, issues for ERP package development and implementation with various kinds of organization and discuss about the Essential factor for ERP Selection and ERP Benefits etc.
Study about the Types of Information Technology Service for Supply Chain Mana...sushil Choudhary
The globalization of company is the excellent object to happen to supply chain management (SCM) in the last 30 years. This study tries to describe the impact of information technology (IT) in supply chain management (SCM). The criteria include the applications of Information Technology (IT) to get the high firm performance comprising marketing performance, financial performance, and customer satisfaction. The information and communication technologies create as one of the biggest consent of the current supply chain management (SCM). This study focuses on one of the vital use of information technologies in SCM background, that is to say Materials Requirement Planning (MRP), manufacturing resource planning (MRP-II), Enterprise resources planning (ERP), SCM-software, Electronic data Interchange, Bar Coding and Scanner, Radio Frequency-Identification technology (RFID) Supply Chain Execution software, Wide Area network (WAN) Technologies, Metropolitan Area network (MAN) Technologies, Local Area network (LAN) Technologies Internet and intranet service etc. These types and ways of information technologies related to supply chain management is examine.
study about the supply chain, flexibility and bullwhip effect on scm in small...sushil Choudhary
The purpose of this work is to study, bullwhip effect on supply chain management and discuss the
develop a conceptual model on the potential barriers in the implementation of supply chain flexibility in small-scale
industries. The model suggests that supply chain flexibility can be researched using a three-tier approach:
identification of risks, identification of potential barriers emerging from these risks, identification of bridges to these
barriers. The proposed is based on the view of problems of small-scale industries as well as the limited research on
supply chain flexibility. The studies indicated that the three main barriers to flexibility in supply chains are
improper integration between systems, Supply Chain Function cost and quickening pace of product innovation.
Some ways to overcome these barriers and act as bridges are also summarized. The field of study of supply chain
flexibility presents numerous options for fresh research work.
Designing the Process of Stores Management for Implementing ERP in Manufactur...sushil Choudhary
This paper describes the importance of ERP in manufacturing industries and examines the various articles
published by eminent Researchers in the field of ERP. Enterprise Resource Planning (ERP) software presents a
frame work for organizations to better utilize their processes. The report is about windows based application.
The main idea of this paper is to handle the all details of stores management system. In this project software
package has been developed to smoothen the processing of item transaction in stores such as item receive, item
issue & report generation such as stock statement, issue register & receive register etc. This Software will help in
automating all the process like receiving and issuing application in stores.
Developed the Inventory Management System for ERP Implementing in Manufacturi...sushil Choudhary
This paper deals with development of inventory management system for a manufacturing Industry. The developed software System is easy to use, less time consuming & all detail about the inventory items & transaction status. Enterprise Resource Planning (ERP) software presents a frame work for organizations to better utilize their processes. The report is about windows based application. The Front-end is developed using Visual Basic. A visual programming environment provides all features that are required to develop graphical user interface as ready to use components. The programmer does not have to write code to create and display commonly required user-friendly features each time around. The Backend used is SQL server database that ensures total security and no data loss or corruption. The database management systems are warehouses of information, where large amount of data can be stored. The Reports are developed using Crystal Report. Crystal Reports is the standard reporting tool for Visual Studio .NET. It brings the ability to create interactive, presentation-quality content; to the .NET platform. Crystal report is an integral part of the Visual Studio .NET environment. The main idea of this paper is to handle the all details of inventory management system. In this software package has been developed to smoothen the processing of item transaction in inventory such as item receive, item issue & report generation such as stock statement, issue register & receive register etc. This Software will help in automating all the process like receiving and issuing application in inventory. Key Words: ERP, Inventory management, Front-end Database SQL, Back end- Visual basic
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.
In the last decades, industrial automation has become a driving force in all production systems. Technologies and architectures have
emerged alongside the growing organizational structures of production plants. Industrial automation plays an important role in industrial and manufacturing environment. Industrial automation means automatically control of industrial appliances which save money, time also reduce human efforts. Automation devices such as controllers and data systems and/or services. Systems and methods are provided that receive statements or other unit of data interaction from an automation device, provide the statements to an appropriate system or service for processing, and optionally return a response such as a result set. In this paper brief study about the automation, level of automation, Industrial automation and types of industrial automation etc.
Latest development of cloud computing technology, characteristics, challenge,...sushil Choudhary
Cloud computing is a network-based environment that focuses on sharing computations, Cloud computing networks access to a shared pool of configurable networks, servers, storage, service, applications & other important Computing resources. In modern era of Information Technology, the accesses to all information about the important activities of the related fields. In this paper discuss the advantages, disadvantages, characteristics, challenge, deployment model, cloud service model, cloud service provider & various applications areas of cloud computing such as small & large scale (manufacturing, automation, television, broadcast, constructions industries), Geographical Information system (GIS), Military intelligence fusion (MIS), business management, banking, Education, healthcare, Agriculture sector, E-Governance, project planning, cloud computing in family etc. Keywords: Cloud computing, community model, hybrid model, Public model, private model
Computer Govern Maintenance System for a Process Industrysushil Choudhary
The present paper deals with development of Computer Govern Maintenance System (CGMS) for a Process
Industry. The developed software is easy to use, less complicated, less costly and less time consuming and
consisting of number of modules like detailed information of equipment, procedures of maintenance tasks,
employees, work order, and calendar facility etc. The software has been developed in Microsoft Visual Studio.NET.
The development of CGMS Software i.e. ‘IOCL CGMS’ at “IOCL Panipat Refinery”, Panipat, may furnish good
results. The currently developed CGMS aims to reduce total downtime, overall annual maintenance cost, frequency
of failures of the machines, to get day-by-day maintenance schedule, maintenance policy.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
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Current Advanced Research Development of Electric Discharge Machining (EDM): A Review
1. International Journal of Research in Advent Technology, Vol.2, No.3, March 2014
E-ISSN: 2321-9637
273
Current Advanced Research Development of Electric
Discharge Machining (EDM): A Review
Sushil Kumar Choudhary 1
(Research Scholar)
&
Dr. R.S Jadoun2
(Professor)
Department1,2
of Industrial & Production Engineering, G.B.Pant University of Agriculture & Technology,
Pantnagar, Uttarakhand, India.
(Sushil_think@rediffmail.com)1
Abstract -Electrical discharge machining (EDM) process is one of the most commonly used non-
conventional precise material removal processes. Electrical discharge machining (EDM) is a process for
shaping hard metals and forming deep complex shaped holes by arc erosion in all kinds of electro-
conductive materials. Erosion pulse discharge occurs in a small gap between the work piece and the
electrode. This removes the unwanted material from the parent metal through melting and vaporizing in
presence of dielectric fluid. In recent years, EDM researchers have explored a number of ways to improve
EDM Process parameters such as Electrical parameters, Non-Electrical Parameters, tool Electrode based
parameters & Powder based parameters. This new research shares the same objectives of achieving more
efficient metal removal rate reduction in tool wear and improved surface quality. This paper reviews the
research work carried out from the inception to the development of die-sinking EDM, Water in EDM, dry
EDM, and Powder mixed electric Discharge Machining. Within the past decade. & also briefly describing
the Current Research technique Trend in EDM, future EDM research direction.
Key Word-Electrical Discharge Machining (EDM), Dry EDM, PMEDM, MRR, TWR, SQ
I INTRODUCTION OF EDM
Electrical Discharge Machining (EDM) is non
traditional, no physical cutting forces between
the tool and the workpiece, high precision metal
removal process using thermal energy by
generating a spark to erode the workpiece. The
workpiece must be a conductive electricity
material which is submerged into the dielectric
fluid for better erosion. EDM machine has wide
application in production of die cavity with large
components, deep small diameter whole and
various intricate holes and other precision part.
. The history of EDM Machining Techniques
goes as far back as 1770, when English chemist
Joseph Priestly discovered the erosive effect of
electrical discharges or sparks. The EDM process
was invented by two Russian scientists, Dr. B.R.
Lazarenko and Dr. N.I. Lazarenko in 1943. The
spark generator used in 1943, known as the
Lazarenko circuit, has been employed over many
years in power supplies for EDM machines and
proved to be used in many current applications.
The Lazarenko EDM system uses resistance-
capacitance type of power supply, which was
widely used at the EDM machine in the 1950's
and later served as the model for successive
development in EDM. Further developments in
the 1960's of pulse and solid state generators
reduced previous problems with weak electrode
as well as the inventions of orbiting systems. In
the 1970's the number of electrodes is reduced to
create cavities. Finally, in the 1980's a computer
numerical controlled (CNC) EDM was
introduced in USA.
The new concept of manufacturing uses non-
conventional energy sources like sound, light,
mechanical, chemical, electrical, electrons and
ions. With the industrial and technological
growth, development of harder and difficult to
machine materials, which find wide application
in aerospace, nuclear engineering and other
industries owing to their high strength to weight
ratio, hardness and heat resistance qualities has
been witnessed. New developments in the field
of material science have led to new engineering
metallic materials, composite materials and high
tech ceramics having good mechanical properties
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and thermal characteristics as well as sufficient
electrical conductivity so that they can readily be
machined by spark erosion. Non-traditional
machining has grown out of the need to machine
these exotic materials.
Fig. 1 Schematic of EDM Process
1
1.
.1
1 C
Co
om
mp
po
on
ne
en
nt
ts
s o
of
f E
ED
DM
M
1. Work-piece-all the conductive material can be
worked by EDM
2. Tool Electrode-The EDM electrode is the tool
that determines the shape of the cavity to be
produce.
3. Dielectric fluid-The EDM setup consists of
tank in which the dielectric fluid is filled.
Electrode & wokpiece submersed into the
dielectric fluid.
4. Servo system-The servo system is commanded
by signals from gap voltage sensor system in the
power supply and control the feed of electrode &
workpiece to precisely match the rate of material
removal.
5. Power supply-The power supply is an
important part of any EDM system. It transform
the alternating current from the main utility
supply into the pulse direct current (DC) required
to produce the spark discharge at the machining
gap.
6. The DC pulse generator is responsible for
supplying pulses at a certain voltage and current
for specific amount of time.
1.2 Principle of EDM
The principle of EDM is to use the eroding effect
of controlled electric spark discharges on the
electrodes. It is thus a thermal erosion process.
The sparks are created in a dielectric liquid,
generally water or oil, between the workpiece
and an electrode, which can be considered as the
cutting tool. There is no mechanical contact
between the electrodes during the whole process.
Since erosion is produced by electrical
discharges, both electrode and workpiece have to
be electrically conductive. Thus, the machining
process consists in successively removing small
volumes of workpiece material, molten or
vaporized during a discharge. The volume
removed by a single spark is small, in the range
of 106
-104
mm3, but this basic process is
repeated typically 10’000 times per second.
Figure 2 (a-e) gives a simple explanation of the
erosion process due to a single EDM discharge.
First, voltage is applied between the electrodes.
This ignition voltage is typically 200 V. The
breakdown of the dielectric is initiated by
moving the electrode towards the workpiece.
This will increase the electric field in the gap,
until it reaches the necessary value for
breakdown. The location of breakdown is
generally between the closest points of the
electrode and of the workpiece, but it will also
depend on particles present in the gap. When the
breakdown occurs, the voltage falls and a current
rises abruptly. The presence of a current is
possible at this stage, because the dielectric has
been ionized and a plasma channel has been
created between the electrodes. The discharge
current is then maintained, assuring a continuous
bombardment of ions and electrons on the
electrodes. This will cause strong heating of the
workpiece material (but also of the electrode
material), rapidly creating a small molten metal
pool at the surface. A small quantity of metal can
even be directly vaporized due to the heating.
During the discharge, the plasma channel
expands. Therefore, the radius of the molten
metal pool increases with time. The distance
between the electrode and the workpiece during
a discharge is an important parameter. It is
estimated to be around 10 to 100 µm. (increasing
gap with increasing discharge current). At the
end of the discharge, current and voltage are shut
down. The plasma implodes under the pressure
imposed by the surrounding dielectric.
Consequently, the molten metal pool is strongly
sucked up into the dielectric, leaving a small
crater at the workpiece surface.
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A. Pre-breakdown-voltage applied
between the electrode and the
workpiece
Fig.2
B. Breakdown-Dielectric breakdown,
creation of the plasma channel
Fig.3
C. Discharge-Heating, melting and
vaporizing of the workpiece material
Fig.4
D. End of the discharge: plasma
implosion, removing of the molten
metal pool.
Fig.5
E. Post-discharge-Solidifying and flushing
of the eroded particles by the dielectric
Fig.6
Fig.( 2 -6 ) Principle of the EDM process
The liquid dielectric plays a crucial role
during the whole process: it cools down the
electrodes, it guarantees a high plasma
pressure and therefore a high removing force
on the molten metal when the plasma
collapses, it solidifies the molten metal into
small spherical particles, and it also flushes
away these particles. The post-discharge is
in fact a crucial stage, during which the
electrode gap is cleaned of the removed
particles for the next discharge. If particles
stay in the gap, the electrical conductivity of
the dielectric liquid increases, leading to a
bad control of the process and poor
machining quality. To enhance the flushing
of particles, the dielectric is generally
flowing through the gap. In addition, the
electrode movement can be pulsed, typically
every second, performing a large retreat
movement. This pulsing movement also
enhances the cleaning, on a larger scale, by
bringing “fresh” dielectric into the gap. The
material removal rate can be asymmetrically
distributed between the electrode (wear) and
the workpiece (erosion). The asymmetry is
mostly due to the different materials of the
electrodes. But it also depends on the
electrode polarity, on the duration of the
discharges and discharge current. Note that
by convention, the polarity is called positive
when the electrode is polarized positively
towards the workpiece, negative otherwise.
By carefully choosing the discharge
parameters, 0.1% wear and 99.9% erosion
can be achieved.
1.3 MAJOR PARAMETERS OF EDM
EDM Parameters mainly classified into two
categories.
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1. Process Parameters 2. Performance
Parameters
1. Process Parameters
The process parameters in EDM are used to
control the performance measures of the
machining process. Process parameters are
generally controllable machining input factors
that determine the conditions in which
machining is carried out. These machining
conditions will affect the process performance
result, which are gauged using various
performance measures.
A. Electrical Parameters
1. Polarity
2. Discharge voltage
3. Gap Voltage
4. Peak Current
5. Average Current
6. Pulse on Time
7. Pulse off time
8. Pulse Frequency
9. Pulse waveform
10. Electrode Gap
11. Duty Factor
B. Non-Electrical Parameters
1. Electrode lifts time
2. Working Time
3. Nozzle flushing
4. Gain
5. Type of Dielectric
C. Powder Based Parameters
1. Powder type
2. Powder concentration 3.Powder size
4. Powder conductivity
5. Powder density
D. Electrode Based Parameters
1. Electrode material 2. Electrode size
3. Electrode shape
2. Performance Parameters-These parameters
measure the various process performances of
EDM results.
Table-1 Performance Parameters
Performance Process performance result
measure
Material
removal rate
(MRR)
MRR is a performance measure
for the erosion rate of the
workpiece and is typically used to
quantify the speed at which
machining is carried out. It is
expressed as the volumetric
amount of workpiece material
removed per unit time.
Tool wear
rate (TWR)
TWR is a performance measure
for the erosion rate of the tool
electrode and is a factor
commonly taken into account
when considering the geometrical
accuracy of the machined feature.
It is expressed as the volumetric
amount of tool electrode material
removed per unit time.
Wear ratio
(WR)
WR is the ratio of TWR/MRR
and is used as a performance
measure for quantifying tool-
workpiece material combination
pairs since different material
combinations gives rise to
different TWR and MRR values.
A material combination pair with
the lowest WR indicates that the
tool-workpiece material
combination gives the optimal
TWR and MRR condition.
Surface
quality (SQ)
Surface quality is a broad
performance measure used to
describe the condition of the
machined surface. It comprises
components such as surface
roughness (SR), extent of heat
affected zone (HAZ), recast layer
thickness and micro-crack
density.
Surface
roughness
(SR)
SR is a classification of surface
parameter used to describe an
amplitude feature, which
translates to roughness of the
surface finish. Of the many
parameters available to quantify
SR, the most commonly used in
EDM are arithmetical mean
surface roughness (Ra),
maximum peak-to-valley surface
roughness (Rmax) and root mean
square surface roughness (Rq).
Heat affected
zone
HAZ refers to the region of a
workpiece that did not melt
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(HAZ) during electrical discharge but has
experienced a phase
transformation, similar to that of
heat treatment processes, after
being subjected to the high
temperatures of electrical
discharge.
Recast layer
thickness
The recast layer refers to the
region of resolidified molten
material occurring as the topmost
layer of the machined surface.
The recast layer is usually located
above the heat affected zone.
1.4 Types of EDM
Basically, there are two types of EDM
1.4.1 Die-sinking
Die Sinker EDM, also called cavity type EDM or
volume EDM consists of an electrode and
workpiece submerged in an insulating fluid such
as, more typically, oil or, other dielectric fluids.
The electrode and workpiece are connected to a
suitable power supply. The power supply
generates an electrical potential between the two
parts. As the electrode approaches the
workpiece, dielectric breakdown occurs in the
fluid, forming a plasma channel, and a small
spark jumps.These sparks usually strike one at a
time because it is very unlikely that different
locations in the inter-electrode space have the
identical local electrical characteristics which
would enable a spark to occur simultaneously in
all such locations. These sparks happen in huge
numbers at seemingly random locations between
the electrode and the workpiece. As the base
metal is eroded, and the spark gap subsequently
increased, the electrode is lowered automatically
by the machine so that the process can continue
uninterrupted. Several hundred thousand sparks
occur per second, with the actual duty cycle
carefully controlled by the setup parameters.
Fig.7 Die Sinking EDM
1.4.2 Wire-cut EDM
Wire EDM Machining (also known as Spark
EDM) is an electro thermal production process in
which a thin single-strand metal wire (usually
brass) in conjunction with de-ionized water (used
to conduct electricity) allows the wire to cut
through metal by the use of heat from electrical
sparks. A thin single-strand metal wire, usually
brass, is fed through the workpiece, submerged
in a tank of dielectric fluid, typically deionized
water. Wire-cut EDM is typically used to cut
plates as thick as 300mm and to make punches,
tools, and dies from hard metals that are difficult
to machine with other methods. Wire-cutting
EDM is commonly used when low residual
stresses are desired, because it does not require
high cutting forces for removal of material. If the
energy/power per pulse is relatively low (as in
finishing operations), little change in the
mechanical properties of a material is expected
due to these low residual stresses, although
material that hasn't been stress-relieved can
distort in the machining process. Due to the
inherent properties of the process, wire EDM can
easily machine complex parts and precision
components out of hard conductive materials.
Wire EDM process produces burr-free
machining and provided that the work-piece is
electrically conductive its mechanical properties
(hardness, toughness, brittleness, and ductility)
impose no limitations on the machining process.
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Fig. 8 wire cut EDM
II-VIBRATION, ROTARY& VIBRO-
ROTARY BASED EDM
In this section various types of approach of
researcher like vibration, rotary & vibro rotary
mechanism based electric discharge machining
Process which enhancement of MRR &
reduction tool Wear & reduced machining cost.
2.1 Research progress in vibration rotary &
Vibro-Rotary EDM
Table-2
Researcher Contribution year wise
Sato et al. (1987) Developed an EDM for micro-
hole boring. They claimed that electrode rotation
served as an effective gap flushing technique,
yielding better material removal.
Murti and Philip (1987) added that with the
combination of ultrasonic vibration in EDM the
MRR and surface finish improved & TWR
increased.
Soni & Chakraverti (1994) introduced rotary disc
for grooving operation on titanium alloy. The
rotary electrode was placed above the work
material. The difficulty of debris problem was
encountered the research work i.e. lower metal
removal rate and arching occurs due to the
accumulation of debris particle between the
electrode and work piece.
Zhang et al. (1997) Spark erosion with ultrasonic
frequency using a DC power supply instead of
the usual pulse power supply. The pulse
discharge is produced by the relative motion
between the tool and work piece simplifying the
equipment and reducing its cost. It is easy to
produce a combined technology which benefits
from the virtues of USM and EDM.
Guo Z.N. et al. (1997) The higher efficiency
achieves by the Employment of ultrasonic
vibration is mainly attributed to the better
circulation of dielectric and debris removal from
work piece.
Soni and Chakraverti (1997) compared the
various performance measures of rotating
electrode with the stationary electrode. The
results concluded an improvement in MRR due
to the better flushing action and sparking
efficiency with little TWR but the surface finish
was improved.
Egashira et al. (1999) adopted to vibrate the
work piece during machining. Micro holes as
small as 5 µ m in diameter in quartz glass and
silicon was machined by EDM with combined
effect vibration. In the machining range, high
tool wear occurs and sintered diamond tool was
used to make machining effective.
Yan et al. (2000) optimized the cutting of
Al2O3/6061Al composite using rotary EDM with
a disk like electrode with Taguchi methodology.
Taguchi methodology revealed that, in general
electrical parameters (Peak Current, Pulse
duration and gap voltage) affects the machining
Performance are MRR, electrode wear rate &
surface roughness more significantly than the
non-electrical parameters: speed of rotational
disc. High MRR was found due to superior
debris disposal effect of RDE.
Ghoreishi and Atkinson (2002) compared the
effects of high and low frequency forced axial
vibration of the electrode, rotation of the
electrode and combinations of the methods
(vibro-rotary) in respect of MRR, TWR & SQ in
EDM die sinking and found that vibro-rotary
increases MRR by up to 35% compared with
vibration EDM and by up to 100% compared
with rotary EDM in semi finishing.
Zhang et al. (2002) The increase in open voltage,
pulse duration, amplitude of ultrasonic vibration
and decrease of wall thickness of the pipe can
give an increase of the MRR. He also found that
oxygen gas can produced greater MRR than air.
Mohan et al.(2004) centrifugal force generate a
layer of dielectric in to the machining gap,
induces an atmosphere for better surface finish,
prevent arching and improves material removal
rate.
Kuo et al. (2004) fabricated the micro disk by the
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application of micro EDM through Wire. The
series-pattern micro-disk was used as a rotating
tool electrode, which is referred to as micro-
rotating disk electrode (MRDE), to
simultaneously achieve micro-slits with widths
as low as 8 µm.
Zhang et al. (2005) found that Material Removal
rate. with the same surface roughness UEDM in
gas is nearly twice as much as EDM in gas but
less than the conventional EDM
Prihandana et al. (2006) work out the effect of
vibratory work piece. It was result out that work
piece vibration increases the flushing effect and
high amplitude combined with high frequency
increase the MRR. Till less research work has
been reported with work piece vibratory motion
by EDM process.
Shih et al. (2007) EDG of AISI D2 tool steel
work piece using a rotary disk copper electrode
Mounted on horizontal spindle. It was observed
that Higher MRR & lower electrode wear.
Chattopadhyay et al. (2008) investigates the
machining characteristics of EN-8 steel with
copper as a tool electrode during rotary electrical
discharge machining process. In the case of
MRR and EWR, it has been seen that the
decrease in pulse on time, decrease in electrode
rotation and increase in peak current, increases
both the machining output, while investigation is
carried out with rotary electrode.
Han et al. [2009] proposed a novel high speed
EDM milling method using moving arc. They
connected a copper electrode rotating rapidly
around its axis and a workpiece to a DC power
supply to generate a moving electric arc. The
electrode was shaped like a pipe in order to
ensure a high relative speed of any point on the
electrode with respect to the workpiece. It was
found that the MRR of EDM milling is almost
four times greater than that of traditional EDM
without any deterioration in surface roughness.
The increase in MRR is due to enhanced duty
cycle during EDM milling.
Xu et al. [2009] introduced a new kind of
electrical discharge machining technology
named tool electrode ultrasonic vibration assisted
electrical discharge machining in gas medium. In
This technology result showed that MRR could
be increased greatly by introducing ultrasonic
vibration. The comparison of MRR in traditional
EDM in gas and ultrasonic vibration assisted gas
medium EDM for machining cemented carbides
workpiece was reported. MRR was found
considerably higher for a particular discharge
pulse-on time for ultrasonic vibration assisted
machining.
G. S. Prihandana et al. [2011] application of low-
frequency vibration in EDM process can be used
to increase the MRR, and decrease the SR and
tool wear rate (TWR).
2.1 Conclusion
Vibration, rotary and vibro-rotary mechanism
makes the equipment simple and increases the
material removal rate, provide better surface
finish ejection from work piece. Better
circulation of dielectric fluid and debris removal
from work piece.
III- WATER IN EDM
Water as dielectric is an alternative to hydro
carbon oil. The approach is taken to promote a
better health and safe environment while
working with EDM. This is because hydrocarbon
oil such as kerosene will decompose and release
harmful vapour (CO and CH4).
3.1 Research progress by using water as
dielectric fluid
Table-3
Year Researcher Contribution
1981 Jeswani M.L [1981]: Machining in
distilled water resulted in higher MRR
and lower wear ratio than in kerosene
when high pulse Energy range was
used.
1984 S. Tariq Jilani et al [1984]: The best
machining rates have been achieved
with tap water as the dielectric
medium; zero TWR possible when
using Cu tool with negative polarities.
1987 Koenig W. et al [1987]: The erosion
process in water based media
consequently possesses higher thermal
stability & much higher power input
can be achieved especially under
critical condition. Use aqueous solution
of organic compounds as medium for
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EDM sinking almost completely
excludes any fire hazard, permitting
safe operation of plant.
1993 Koenig W. et al [1993]: EDM sinking
process can be made more cost
effective through the use of water based
media, significantly improving
competitiveness with other process.
Yoshiro et al [1993]: A machine tool
maker has established technologies for
water-immersion machining, greatly
improved the surface finish so that post
process manual polishing is not
required.
1995 Kruth J.P et al [1995]: Water dielectric
cause decarbonisation in the white
layer at the surface of a work piece
while oil dielectric increase the carbon
content in the white layer appears as
iron carbide in columnar.
1999 Chen S.L. et al [1999]: The MRR is
greater and the relative wear ratio is
lower when machining in distilled
water rather than in kerosene.
2004 Leao & Pashby [2004]: Water based
dielectrics may replace oil-based fluids
in die sinking applications.
2005 Yan B.H. et al [2005]: TiN was
synthesized on the machined surface by
chemical reaction that involved
elements obtained from the work piece
and the urea solution in water as
dielectric during EDM: the surface
modification of pure titanium metals
exhibited improved friction and wear
characteristics.
Ekmekci. B. et al [2005]: Stresses are
found to be increasing rapidly with
respect to depth, attaining to its
maximum value around the yield
strength and then fall rapidly to
compressive residual stresses in the
core of the material since the stresses
within plastically deformed layers are
equilibrated with elastic stresses.
Kang & Kim [2005]: In the case of the
kerosene electrical discharge (ED)
machined specimens, it was observed
that carburization and sharp crack
propagation along the grain boundary
occurred after the heat treatment.
However, the deionized ED machined
specimen after the heat treatment
underwent oxidation and showed no
crack propogation behaviour.
Sharma A. et al. [2005] investigated
the potential of electrically conductive
chemical vapor deposited diamond as
an electrode for micro-electrical
discharge machining in oil and water.
While doing a comparative study on the
surface integrity of plastic mold steel,
2008 Han-Ming Chow et al. [2008] using
pure water as an EDM dielectric fluid
for titanium alloy yields a high MRR
and relatively low electrode wear and
small expanding-slit by employing
negative polarity (NP) processes.
3.2 Conclusion
Water-based dielectric can replace hydrocarbon
oils since it is environmentally safe. Water based
EDM is more eco friendly, reduced harmful
agent, toxic fumes dangerous for human &
economically low cost machining as compared to
conventional oil based dielectric. The material
removal rate enhanced with use of water.
IV- DRY EDM
Dry EDM is a green environment friendly
Electric discharge machining Technique in
which the liquid dielectric is replaced by a
gaseous dielectric. Gas at high pressure as used
as the dielectric medium. In dry EDM, tool
electrode is formed to be thin walled pipe. 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.
Tool rotation during machining not only
facilitates flushing but also improves the process
stability by reducing arcing between the
electrodes The technique was developed to
decrease the pollution caused by the use of liquid
dielectric which leads to production of vapor
during machining and the cost to manage the
waste. Dry EDM method with the shortest
machining time compare to oil die sinking EDM,
& lowest electrode wear ratio. Work removal
rate also get enhanced by dry EDM.
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Fig. 9 Principle of Dry EDM
4.1 Research Progress in Dry EDM
Table-4
Researcher contribution Year wise
Kunieda et. al. [1991]: oxygen gas introduced in
discharge gap based dielectric in water increased
removal rate.
Kunieda et al [1997]: Electrical discharge
machining can be achieved in gas.
Yoshida et al [1999]: tool electrode is almost
negligible for any pulse duration in dry EDM.
Kunieda et al [2001]: narrower gap, no corrosion
of work piece and high finish cutting in dry EDM.
Zhang et al [2002]: EDM with ultrasonic aid
(UEDM) can be achieved in gas medium.
Wang et al [2003]: dry EDM removes
environmental pollution due to liquid dielectric.
Better straightness with dry EDM.
Kunieda et al [2003]: oxidation of work pieces due
to the usage of oxygen electrode wear is almost
negligible increase MRR.
Curodeau et al [2003]: a thermoplastic composite
electrode used in dry EDM using air as dielectric
medium.
Z. B. Yu et al [2003]: dry EDM is suitable for 3D
milling of difficult to cut materials such as
cemented carbide.
Kunieda et al [2004]: improvement of dry EDM by
controlling the discharge gap using a piezoelectric
actuator.
Wang T. et al [2004]: the explosive force and
electrostatic force acting on wire electrode
decrease in dry WEDM.
Zhang et al [2004]: ultrasonic vibration improves
MRR in gas by increasing the effective discharge.
Li L.Q [2004]: discharge passage extends rapidly
in the gas medium of dry EDM.
Zhang et al [2005]: a theoretical model of surface
roughness in ultrasonic vibration assisted EDM
(UEDM) in gas.
ZhanBo et al. [2006]: Optimum combination of
depth of cut, gas pressure & pulse duration 25µm
it is lead to maximum material removal rate &
minimum tool wear.
Shue k. Y. et al. [2010]: Dry Electrical discharge
machining (Dry EDM), using gas as dielectric, has
been developed to solve problems against
environment. It has both advantages of high
material removal ratio (MRR) and low relative
electrode wear ratio (REWR
Masahiro Fujiki [2011]: Achieve high material
removal rate in tool path planning for the near-dry
electrical discharge machining (EDM) milling
process using tubular electrode with a lead angle.
Wang T. et. al. [2013]: Main advantages of dry
finishing of WEDM such as better straightness,
lower SR and shorter gap length.
Roth R. et al. [2013]: Heat energy from the
oxidation has only a little effect on the material
removal rate and that the main difference between
oxygen and less oxidizing gases is to find in
different stability and time efficiency of the
process.
4.2 Conclusion
Dry EDM is eco friendly machining. Pollution is
reduced by use of gas instead of oil based
dielectric. Harmful & toxic fumes are not
generated during machining. Material removal
rate &electrode wear ratio also get enhanced by
dry EDM. This technique should be supported
and more investigation should be made since it
helps to save the environment.
V- POWDER MIXED EDM
Powder mixed electric discharge machining
(PMEDM) is one of the new innovations for the
enhancement of capabilities of electric discharge
machining process. In this process, a suitable
material in fine powder is properly mixed into
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the dielectric fluid. The added powder improves
the breakdown characteristics of the dielectric
fluid. The insulating strength of the dielectric
fluid decreases and as a result, the spark gap
distance between the electrode and work piece
increases. Enlarged spark gap distance makes the
flushing of debris uniform. This results in much
stable process thereby improving material
removal rate and surface finish.
When voltage is applied the powder particles
become energized and behave in a zigzag
fashion. These charged particles are accelerated
due to the electric field and act as conductors
promoting breakdown in the gap. This increases
the spark gap between tool and the work piece.
Under the sparking area, these particles come
close to each other and arrange themselves in the
form of chain like structures. The interlocking
between the powder particles occurs in the
direction of flow of current. The chain formation
helps in bridging the discharge gap between the
electrodes. Because of bridging effect, the
insulating strength of the dielectric fluid
decreases resulting in easy short circuit. This
causes early explosion in the gap and series
discharge’ starts under the electrode area. The
faster sparking within a discharge causes faster
erosion from the work piece surface and hence
the material removal rate increases.
Fig.10 working principle of PMEDM
5.1 Research Progress in Powder mix Dielectric Electric discharge Machining (PM-EDM)
Table-5
Author/year Process
parameters
Tool
Electrode
Workpiece Research finding
Ming, Q.Y. et
al.
(1995)
Current
Pulse width,
Pulse interval,
Additives
powder
concentration
Copper high-carbon
steel
• The surface roughness decreased with
increase in powder concentration, but
increased with excessive powder
concentration.
• The tendency for crack inception and
extent of crack propagation on the
machined surface was reduced.
• The recast layer was thinner and
denser
Tzeng, Y.F.
et al. (2001) Aluminium
chromium
copper &
silicon carbide
powders
concentration
Copper SKD-11 • The discharge gap distance and
material removal rate increased as
powder granularity was increased.
• Of the powder materials capable of
remaining in suspension during
machining, aluminium produced the
largest discharge gap enlargement and
silicon carbide produced the smallest.
Zhao, W.S., Pulse on time Copper Steel • PMD-EDM was applied to improving
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et al.
(2002 )
Peak current
Discharge gap
Pulse width
Concentration
of Al powder
workpiece the efficiency of rough machining.
• PMD-EDM enabled a 70 %
improvement in machining efficiency
over EDM in powder-free dielectric
while achieving similar machined
surface roughness
Pecas p. et al.
(2003)
Peak current
Duty Cycle
Polarity
Flushing
Concentration
of Si powder
Electrolyt
ic Copper
AISI H13 • The positive influence of the Si
powder in the reduction of the
operating time, achieve a specific SQ,
and in the decrease of the SR,
allowing the generation of mirror-like
surfaces.
Klocke, F., et
al.
(2004 )
Polarity
Voltage
Pulse duration
Duty Cycle
Concentration
of Al,& Si
powder.
Tungsten
electrodes
Inconel 718
superalloy
• The powder additives caused greater
expansion of plasma channel
compared to a powder-free dielectric.
• The powder additives changed the
thermal material removal mechanism
and affected the composition and
morphology of the recast layer.
Tzeng, Y.F.
et al. (2005) Peak current
Pulse on time
Duty cycle
Powder size,
Powder
Concentration
of Al. Cr Cu,
Si.
Copper SKD-11 • The presence of powder additives
reduced the recast layer thickness.
• The surface roughness decreased
when aluminium powder granularity
was decreased.
• The RLT decreased when aluminium
powder granularity was increased.
• Aluminium powder material produced
the smallest surface roughness and
thinner recast layer.
Kansal et al.
(2005)
Pulse on time,
Duty cycle,
Peak current,
Concentration
of the added
Si powder
Copper EN 31 tool
steel
• MRR increased with the increase in
the concentration of silicon powder.
• Surface roughness improves with
increased concentration of silicon
powder.
Kansal H. K.
et. al. (2006)
Peak current,
pulse duration,
Duty cycle,
Concentration
of silicon
powder
Copper H-11 Die
Steel
• The concentration of Added silicon
powder, pulse duration, & peak
current significantly affect the
material removal rate & Surface
roughness in powder mix electrical
discharge machining.
• Addition Of appropriate quantity of
silicon powder into dielectric fluid of
EDM enhances the material erosion
rate.
Kansal H. K.
et. al. (2007)
peak current,
pulse on time,
pulse-off time,
concentration
of powder,
gain, and
nozzle
Copper AISI D2
Die Steel
• The concentration of Si powder into
the dielectric fluid of EDM
appreciably enhances material
removal rate.
• Peak current, concentration of the Si
powder, pulse-on time, pulse-off time,
& gain significantly affect the MR in
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flushing PMEDM.
• The nozzle flushing when applied at
the interface of tool electrode and
workpiece does not significantly
affect the MR.
Furutani, K.,
et al.
(2009)
Discharge
current, Pulse
duration,
Concentration
of Titanium
Powder
copper Titanium
carbide
• PMD-EDM was applied to accretion
process.
• Deposition of TiC was possible at
discharge energies below 5 mJ under
certain discharge current and pulse on
time combinations.
• There existed a maximum discharge
current for deposition.
• The larger the discharge current, the
smaller the range of pulse on time
durations available for deposition.
Sharma s.
et al. (2010)
concentration
of Al. powder
and the grain
size of the
Powder
particles,
Reverse
Polarity
Current,
voltage, pulse
on time, duty
cycle
Copper Hastelloy • The surface roughness of the work
material continuously decreases with
the increase in the concentration of
aluminium powder and with change in
the grain size of the powder particles.
• With the increase in the concentration
of the powder, percentage wear rate
decreases sharply.
• With change in the grain size of the
powder, the percentage wear rate
decreases continuously.
• With the increase in the concentration
of additive powder in the dielectric
fluid, the tools wear increases.
• With the addition of aluminium
powder in the dielectric fluid of EDM,
the material removal rate increases.
Singh P. et al.
(2010)
Concentration
s of aluminum
powder and
grain size of
powder
Copper
electrode.
Hastelloy • The addition of Al powder in
dielectric fluid increases MRR,
decreases TWR and improves surface
finish of Hastelloy.
Singh G. et
al. (2012)
Polarity,
peak Current,
pulse on time,
duty Cycle,
gap Voltage,
Concentration
of abrasive
Powder
Copper H 13 steel • Negative polarity of tool electrode is
desirable lowering of surface
roughness.
• Increasing pulse on time leads to
produce more rough surfaces.
• Addition of powder particles in
dielectric fluid decreases surface
roughness of specimen in EDM
process.
• Higher peak currents produce more
rough surfaces in EDM process.
Syed &
Palaniyandi
peak current,
pulse on-time,
electrolyti
c copper,
W300 die-
steel
• Uses distilled water mixed with
aluminium powder improve the
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(2012) Polarity,
Concentration
of Al powder,
performance of MRR, SR & WLT.
• High MRR, is obtained in positive
polarity, whereas better surface
quality (surface roughness and white
layer thickness) is achieved in
negative polarity. Hence for rough
machining positive polarity can be
selected to achieve higher MRR and
during finishing a better surface is
achieved by changing the polarity.
Mathapathi
U. et al.
(2013)
Pulse on time,
Pulse off time
Peak current
Tool electrode
lift time,
Concentration
of graphite &
Cr powder
Copper ASI
D3/HCHCR
• TWR in PMEDM is smaller as
compared with the conventional
EDM.
• MRR has increased by adding the
powder in dielectric fluid as compared
with conventional EDM.
• MRR is maximum effected by the
increase of peak current.
• MRR has been decreased by
increasing the pulse off time.
• As the tool electrode lift time has
increased, the MRR.
Muniu J.M.
et al. (2013)
Concentration
of Copper,
Diatomite,
Aluminium
Graphite Mild steel • MRR for copper, aluminium and
diatomite powder increases to
maximum and then decreases with
further increase in powder
concentration.
Goyal S. et
al.(2014)
Current,
Voltage, Pulse
on time, Duty
factor
Grain size of
Al. powder &
Concentration
of Al powder
Copper AISI 1045
steel
• Mixing of Aluminium (Al) powder in
Di-electric fluid ensures improved
Metal removal rate and surface
finishing.
5.2 Conclusion
Use of powder mix in electrolyte provide mirror
like surface finish, increase in material removal
rate, Totally Burr free ,& no stresses produced in
work piece. Proper work piece and powder
combination must be used for better results.
VI- FUTURE EDM RESEARCH DIRECTION
The EDM research area can be divvied into four
different major areas.
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Fig. 11 Classification
6.1 Performance measurement improvement
This can be done by the use of CNC to EDM for
facilitating the MRR and improving the tool wear
compensation techniques, it results the potential of
using simple tooling to generate complex 3D cavity
without employing a costly 3D profile electrode.
This technique benefits the EDM process by
reducing the large proportion of cost and time
factors of producing the electrode which account
for almost 45% of the total machining cost.
6.2 Monitoring and control of the process
The monitoring and control of the EDM process are
often based on the identification and regulation of
adverse condition occurring during the sparking
process. Most of the approaches measure pulse and
time domain parameters to differentiate the arc
pulses from the rest EDM pulses. The option of
using emitted RF has also been experimented but
generates very little research. The application of
fuzzy logic to the adaptive control system provides
a reliable pulse discriminating role during the EDM
process. Several authors claimed that the fuzzy
logic control implements a control strategy that is
adopted by a skilled operator to maintain the
desired machining process. Tarng et al. [1997]
suggested a fuzzy pulse discriminator established
on the linguistic rules acquired from the knowledge
of experts and expressed mathematically through
the theory of fuzzy sets. However, the definition of
membership functions for each fuzzy set is not
straightforward and is based on exploratory means
to classify various discharge pulses. Radio
frequency (RF) or HF signal generated during EDM
has been used to monitor and control the sparking
process. Radio Frequency monitoring system
providing a pulse control to the machine power
generator by examining the RF signal created from
the spark gap. The RF monitoring system detects
any drop in the intensity of signals to a threshold
value whenever the discharge changes from
sparking to arcing.
6.3 Development of EDM
With the help of different advances in the EDM
machine has increased the applications of EDM
process. It is used in the automotive industry,
aerospace industry , nuclear industry, mould, tool
and die making industries. EDM is also used in
machining of medical, dental, optical equipments,
jewellery industries. For this we need the
machining req. such as the machining of HSTR
materials, which generate strong research interest
and increase the EDM machine manufacturers to
improve the machining characteristics. One of the
unique options of improving the machining
performance involves the HMP combining EDM
process with other material removal processes. The
most popular and highly effective arrangement
includes the USM delivering ultrasonic vibration to
the electrode, which assists the sparking and
flushing operations. However, Taylan et al. [2001]
noted that the current trend in tool and die
manufacturing is towards replacing the EDM
process with new machining techniques such as
HSM. HSM process is just as capable as the EDM
process in machining hardened materials with 40–
60 HRC. Therefore, HMP involving EDM will
continue to draw intense research interests seeking
innovative ways of improving the machining
performance and expanding the EDM applications
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6.4Optimizing the process variable
In these days, the most effective & economically
machining approach is determined by finding the
different factors affecting the EDM process and
tries to find the ways of obtaining the optimum
machining condition and performance. In this
categories provide a study of several machining
strategies including design of the process
parameters & modeling of the EDM Process. The
EDM process has a very strong stochastic nature.
Due to the complicated discharge mechanisms
making it difficult to optimize the sparking process.
The optimisation of the process often involves
relating the various process variables with the
performance measures maximising the MRR, while
minimising the TWR and yielding the desired SR.
In many cases, S/N ratio together with the help of
analysis of variance (ANOVA) technique we
measure the amount of variation from the desired
performance and find out the various important
process variables affecting the process response.
VII- MAJOR RESEARCH DEVELOPMENT
IN EDM RESULTING IN MRR
IMPROVEMENT
In this paper, review of EDM research work related
to MRR improvement has been presented along
with some insight into the basic Electric Discharge
machining (EDM) process MRR mechanism. The
major research development resulting in
improvement in material removal rate (MRR) &
Reduction tool wear is summarized in Table-6.
Table-6
S.
No.
Researcher contribution
year wise
Workpiece
material
Electrode
material
Electrical
Parameters
Non-
Electrical
parameters
1. Bayramoglu and Duffill
(1995) Investigated frame type
cutting tool with CNC EDM
for generation of linear,
circular and curved contours.
Mild steel Copper Voltage,
current,
on- time,
off -time
Non
2. Ming and He (1995),
Investigated the effect of
powder suspension in
kerosene oil used as dielectric.
High carbon
steel and
high
alloy steel
Copper Current,
pulse
interval
Non
3. Wong et al. (1995)
Investigated the influence of
flushing on the efficiency and
stability of machining
condition.,
AISI 01 tool
steel
Copper Voltage,
current,
pulse
duration,
polarity
Flushing rate
4. Kunieda and Yoshida, (1997)
Investigated dry EDM method
and compared its performance
with EDM in oil.
Steel (S45C) Copper Voltage,
current,
Pulse
duration,
polarity
Wall thickness of pipe
electrode,
air
pressure, rotation and
plenary motion of tool
5. Wong et al.,(1998)
Investigated the near mirror-
finish phenomenon in EDM
with fine powder suspension
in dielectric.
SKH-54 tool
steel
copper Spark
gap, pulse
duration,
polarity
Powder
suspension
type and
properties
6. Chen et al.,(1999) Investigated
Machining characteristics with
kerosene and distilled water as
the dielectrics.
Titanium
alloy (Ti–
6A1–4V)
Copper Current,
pulse
duration
Type of
dielectric
fluid
7. Wang and Yan.,(2000)
Compared the performance of
Al2O3/6061
Al
Copper polarity,
peak current,
Electrode
rotation,
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stationary electrode, a
rotational electrode, and a
rotational electrode with an
eccentric through-hole terms
of machining characteristics.
composite pulse
duration,
supply
voltage
flushing
pressure
8. Kunieda and Muto (2000)
Investigated and compared
machining characteristics of
Multi-spark EDM electrode
with those of conventional
EDM electrode.
steel SUJ2 Copper Voltage,
current,
polarity
Non
9. Aspinwall (2001) Investigated
hybrid high speed machining
process (EDM/HSM).
Steel Graphite Voltage Electrode
rotation
10. Tzeng and Lee (2001)
Investigated the effects of
various powder characteristics
on the efficiency of PMEDM.
SKD11 Copper Spark
gap,
current,
pulse-on
time
Powder
suspension
type
11. Zhao et al.(2002) Performed
Experimental research on
Machining efficiency and
Surface roughness of PMEDM
in rough machining.
Steel Copper Current,
pulse-on
time,
pulse-off
time
Non
12. Ghoreishi and Atkinson
(2002) Investigated and
compared the effect of high
and low frequency forced
axial vibration, electrode
rotation and combination of
these methods on performance
measures.
Tool and die
steel A1S1
01
Copper Open
voltage,
Discharge
voltage, tool
polarity
Amplitude of
ultrasonic and
low frequency
vibration, electrode
rotation, Frequency of
vibration
13. Zhang et al.(2002) Proposed
and Investigated ultrasonic
vibration Electrical discharge
machining
Steel Copper Voltage,
pulse
duration,
Pipe wall
thickness,
electrode,
vibration
amplitude,
effects of gas
medium
14. Kunieda et al.(2003)
Investigated high speed EDM
milling of 3D cavities using
gas as the working fluid
Mild steel
(SS400)
Copper Discharge
current,
discharge
duration,
discharge
interval
Non
15. Mohan et al. (2004)
Investigated Effect of tube
electrode rotation on
performance measures.
6025 Al-
alloy
reinforced
with SiC
particles
Brass Peak
current,
polarity,
pulse
duration
Electrode rotation, volume
fraction of SiC
reinforced
particles, hole
diameter of
tube electrode
16. Bayramoglu and Duffill
(2004) Investigated plate type
tool and compared the
Steel Copper Voltage,
current,
on- time,
Non
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performance with 3 D form
tool.
off -time
17. Yu et al.(2004) Compared
Machining characteristics
between dry EDM milling, oil
EDM milling and oil die
sinking EDM
Cemented
carbide
Copper
tungsten
Discharge
current,
discharge
duration,
discharge
interval
Electrode
rotation
18. Singh et al. (2005) Optimize
the Process parameters of
powder mixed electrical
discharge machining by using
response surface methodology.
EN 31 tool
steel
Copper Pulse on
time, Duty
cycle,
Peak
current
Concentration
of the added
silicon
powder
19. Zhang et al. (2006) Applied
ultrasonic to improve the
efficiency in EDM in gas
medium
AISI 1045
steel
Copper Open
voltage,
Pulse
duration,
Discharge
current
Gas pressure,
Wall thickness,
actuation
amplitude
20. Kansal et al. (2006)
Performance parameters
optimization (multi
characteristics) of powder
mixed Electric discharge
Machining (PMEDM)
Through Taguchi’s method
utility concept.
H-11 Die
Steel
Copper Peak
current,
pulse
duration,
Duty cycle,
Concentration of silicon
powder
21. Kansal et al. (2007) Effect of
Silicon Powder Mixed EDM
on Machining Rate of AISI D2
Die Steel
AISI D2 Die
Steel
Copper peak current,
pulse on
time, pulse-
off time,
concentration of powder, gain,
and
nozzle flushing
22. Chen et al.(2008) Introduced a
New mechanism of cutting
pipe combined with electrical
discharge machining
SUS 304 Copper Peak
current,
pulse
duration,
polarity
Workpiece
rotation
23. Han et al. (2009) Proposed a
Novel high speed electrical
discharge machining (EDM)
milling method using moving
electric arcs.
Mold steel Copper Open
voltage,
Peak
current,
Duty cycle
Electrode
revolution
24. Xu et al. (2009) Proposed the
tool electrode ultrasonic
Vibration assisted EDM in gas
medium and introduced its
principle.
YT15
cemented
carbide
Copper Voltage,
current
pulse on
time
Frequency
And amplitude of ultrasonic
vibration,
25. S.H. Tomadi et. al. (2009)
Analysis of the Influence of
EDM Parameters on Surface
Quality Material Removal
Rate and Electrode Wear of
Tungsten Carbide.
Tungsten
Carbide
(WC-Co )
Copper
tungsten
peak current,
power
supply
voltage,
Pulse on
time, pulse
off time.
Non
26. Iqbal & Khan (2010) Stainless Copper Voltage & Rotational speed of the
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Influence of Process
Parameters on Electrical
Discharge Machined Job
Surface Integrity.
steel AISI
304
feed rate electrode
27. B. Sidda Reddy et. al. (2010)
Parametric study of electrical
Discharge machining of
ASI304 Stainless steel.
Stainless
steel AISI
304
Copper Current,
Open
circuit-
voltage,
Servo and
duty cycle.
Non
28. Kuldeep Ojha et. al. (2011)
Parametric Optimization of
PMEDM Process using
Chromium Powder Mixed
Dielectric and Triangular
Shape Electrodes.
EN-8 steel copper Average
current,
duty cycle,
Angle of electrode and
concentration of chromium
powder added into dielectric
fluid of EDM
29. Shabgard1 M. et. al. (2011)
Influence of Input Parameters
on the Characteristics of the
EDM Process.
AISI H13
tool steel
copper Pulse on-
time and
pulse
current.
Non
30. Harpuneet Singh (2012)
Investigating the Effect of
Copper Chromium and
Aluminum Electrodes on EN-
31 Die Steel on Electric
Discharge Machine Using
Positive Polarity.
EN-31 die
steel
Copper
chromium
and
Aluminum
pulsed
current
Positive
Polarity
Non
31. Vishwakarma M. et. al.(2012)
Response surface approach for
optimization of Sinker Electric
Discharge Machine process
parameters on AISI 4140 alloy
steel
AISI 4140
Grade steel
alloy.
Copper Discharge
current
Pulse-on
time
Duty Cycle
Gap Voltage
Flushing Pressure
32. Syed & Palaniyandi (2012)
Performance of electrical
discharge machining using
aluminium powder suspended
distilled water
W300 die-
steel
electrolytic
copper,
peak current,
pulse on-
time,
Polarity
concentration of the powder,
33. Belgassim and Abusada
(2012) Optimization of the
EDM Parameters on the
Surface Roughness of AISI
D3 Tool Steel.
AISI D3
Tool Steel
Brass Pulse
current
Pulse –on
time Pulse –
off time and
Gap voltage
Non
34. Gurule & Nandurkar (2012)
Effect of Tool Rotation on
Material Removal Rate during
Powder Mixed Electric
Discharge Machining of Die
Steel.
Die steel D2 Cu, brass
Al
Pulse
current
Pulse –on
time Pulse –
off time
Suspension of Al powder
concentration,
Tool rotation,
Flushing pressure,
35. Reza Atefi et. al., (2012) The
Investigation of EDM
Parameters in Finishing Stage
hot work
steel
DIN1.2344
Copper pulse
current,
pulse
Non
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on Surface Quality Using
Hybrid Model
voltage,
pulse on-
time, pulse
off-time)
36. Bharti S. P .et al.,(2012) Multi
objective optimization of
electric discharge machining
process using controlled elitist
NSGA-II.
Inconel 718 Copper Discharge
Current
Pulse-on
time
Duty cycle
Gap Voltage
Shape factor (SF)
Flushing pressure
Tool Electrode Lift
37. Singh G. et. al., (2012) effect
of machining parameters on
surface Roughness of H 13
steel in EDM process using
Powder mixed fluid.
H 13 steel Copper Polarity,
peak
Current,
pulse on
time,
duty Cycle,
gap Voltage
Concentration of abrasive
Powder
38. M. Gostimirovic et al. (2012)
Effect of electrical pulse
parameters on the machining
performance in EDM.
Manganese-
vanadium
tool steel
Graphite
tool
Electrode
Discharge
current &
pulse
duration
non
39. Khan F. et al. (2012)
Experimental Investigation of
Machining of Al/SiC MMC on
EDM by using Rotating and
Non-Rotating Electrode
Al/SiC
MMC
pulse on
time, pulse
off time,
voltage and
peak current
Rotating and Non-Rotating
Electrode
40. S. Sivasankar et. al. (2013)
Performance study of tool
Materials and optimization of
Process parameters during
EDM On ZrB2-SiC composite
through Particle swarm
optimization Algorithm.
ZrB2-SiC
composite
graphite,
titanium
niobium,
tantalum
and tungsten
pulse on
time, pulse
off time
Non
41. Jai Hindus.S et. al. (2013)
Experimental Investigation on
Electrical discharge machining
of SS 316L.
SS 316 L Copper Current
Pulse –on
Time
Non
42. Balbir Singh et. al. (2013)
Investigating the Influence of
Process Parameters of ZNC
EDM on Machinability of
A6061/10% SiC Composite.
A6061/10%
SiC
Composite
copper current, gap
voltage,
pulse-on
time, and
pulse-off
time
non
20. International Journal of Research in Advent Technology, Vol.2, No.3, March 2014
E-ISSN: 2321-9637
292
43. Goyal S. et al.(2014)
Parametric Study of Powder
Mixed EDM and
Optimization of MRR &
Surface Roughness
AISI 1045
steel
Copper Current,
Voltage,
Pulse on time,
Duty factor
Grain size of Al. powder &
Concentration of Al.
powder
7. SUMMARY
Recent advancements in various aspects of electro-
discharge machining that reflect the state of the art
in these processes are presented in this review
paper. Researcher works on enhancement of
material removal rate (MRR), reduction of tool
wear rate (TWR), improve Surface Quality (SQ) by
experimental investigation. Various approaches
like Vibration, rotary and Vibro-rotary mechanism
based EDM, water based EDM has been employed
for increase of EDM efficiency, Dry EDM use of
gas instead of oil electrolyte, PM-dielectric Electric
Discharge Machining. It also plays a significant
role in medical, optical, Jewellery, automotive and
aeronautic industry & making a various mechanical
component in manufacturing industries.
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