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)
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.
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.
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)
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.
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.
Thermal Stress Analysis of Electro Discharge MachiningIJESFT
Procedures and results of experimental work to find thermal stress analysis in electric discharge machined surfaces are presented. In this study, an axisymmetric thermo-physical FEA model for the simulation of single sparks machining during electrical discharge machining (EDM) process is shown. This model has been solved using ANSYS 14.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties is used to investigate the stress analysis based on temperature distribution. The effect on significant machining parameters (Gap current – Gap voltage) on aforesaid responses had been investigated and found that the stresses sharply changes with the parameters [1].
The FEA model is used to study the relation between these parameters and maximum temperature attended at the end of cycle which is further used to find residual stress produced at the end of cooling cycle. To find residual stresses in the work piece during EDM, the temperature distribution at the end of pulse duration in the work piece has to be estimated [2]
High residual thermal stresses are developed on the surfaces of electric discharge machined parts because of the high temperature gradients generated at the gap during electrical discharge machining (EDM) in a small heat-affected zone. These thermal stresses can be responsible for micro-cracks, decrease in fatigue life and strength and possibly catastrophic failure. The results of the analysis show high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength. A transient thermal analysis assuming a Gaussian distribution heat can be used to investigate the Stress analysis.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
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.
CW RADAR, FMCW RADAR, FMCW ALTIMETER, AND THEIR PARAMETERSveerababupersonal22
It consists of cw radar and fmcw radar ,range measurement,if amplifier and fmcw altimeterThe CW radar operates using continuous wave transmission, while the FMCW radar employs frequency-modulated continuous wave technology. Range measurement is a crucial aspect of radar systems, providing information about the distance to a target. The IF amplifier plays a key role in signal processing, amplifying intermediate frequency signals for further analysis. The FMCW altimeter utilizes frequency-modulated continuous wave technology to accurately measure altitude above a reference point.
Thermal Stress Analysis of Electro Discharge MachiningIJESFT
Procedures and results of experimental work to find thermal stress analysis in electric discharge machined surfaces are presented. In this study, an axisymmetric thermo-physical FEA model for the simulation of single sparks machining during electrical discharge machining (EDM) process is shown. This model has been solved using ANSYS 14.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties is used to investigate the stress analysis based on temperature distribution. The effect on significant machining parameters (Gap current – Gap voltage) on aforesaid responses had been investigated and found that the stresses sharply changes with the parameters [1].
The FEA model is used to study the relation between these parameters and maximum temperature attended at the end of cycle which is further used to find residual stress produced at the end of cooling cycle. To find residual stresses in the work piece during EDM, the temperature distribution at the end of pulse duration in the work piece has to be estimated [2]
High residual thermal stresses are developed on the surfaces of electric discharge machined parts because of the high temperature gradients generated at the gap during electrical discharge machining (EDM) in a small heat-affected zone. These thermal stresses can be responsible for micro-cracks, decrease in fatigue life and strength and possibly catastrophic failure. The results of the analysis show high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength. A transient thermal analysis assuming a Gaussian distribution heat can be used to investigate the Stress analysis.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
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.
CW RADAR, FMCW RADAR, FMCW ALTIMETER, AND THEIR PARAMETERSveerababupersonal22
It consists of cw radar and fmcw radar ,range measurement,if amplifier and fmcw altimeterThe CW radar operates using continuous wave transmission, while the FMCW radar employs frequency-modulated continuous wave technology. Range measurement is a crucial aspect of radar systems, providing information about the distance to a target. The IF amplifier plays a key role in signal processing, amplifying intermediate frequency signals for further analysis. The FMCW altimeter utilizes frequency-modulated continuous wave technology to accurately measure altitude above a reference point.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
6th International Conference on Machine Learning & Applications (CMLA 2024)ClaraZara1
6th International Conference on Machine Learning & Applications (CMLA 2024) will provide an excellent international forum for sharing knowledge and results in theory, methodology and applications of on Machine Learning & Applications.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
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.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
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.
1. CONTENT
What is EDM
Working principle
Elements of EDM
Process capabilities
Measurement of MRR and Electrode wear
Applications
Advantages
Disadvantages
2. ELECTRIC DISCHARGE MACHINING
It is thermal energy based advance machining process. Numerous tiny
sparks created between two electrodes (Tool and Workpiece) are
responsible for melting and vaporization of work material.
3. WORKING PRINCIPLE
EDM is a thermoelectric process in which heat energy of a spark is used to
remove material from the workpiece in the presence of dielectric fluid.
The workpiece and tool should be made of electrically conductive material.
The frequency of sparking may be as high as thousand of spark per second.
The material removed from w/p in the form of craters. Particles erode from
electrode known as debris.
Electrodes are submerged in dielectric so that energy concentrated into
small area. Cooling of electrodes is also function of dielectric.
Localized spark energy Very high temperature
Melting & vaporization
of tool & w/p
4. Pulse On-time and Pulse Off-time
• Pulse On-time: The duration time of the EDM
spark measured in microseconds. During the
on-time there will be vaporization of material
i.e. melting of electrode material, The larger
the on time the more the metal erodes.
• Pulse Off-time: As soon as the off-time of a
pulse starts, the pressure drops instantaneously
allowing the superheated metal to evaporate.
The amount of material eroded from the work
piece and the tool will depend upon the
contributions (in the form of K.E) of electrons
and ions.
6. DIELECTRIC SUPPLY SERVO SYSTEM
POWER SUPPLY TOOL & WORKPIECE
ELEMENTS OF EDM
Power supply converts AC to DC by using solid state rectifier to
produce spark between tool and workpiece.
Power supply should also be able to control the parameters like
voltage, current, duration and frequency of a pulse, electrode polarity
etc.
EDM power supplies are also equipped with cut-off protection circuit.
7. DIELECTRIC SUPPLY SERVO SYSTEM
POWER SUPPLY TOOL & WORKPIECE
ELEMENTS OF EDM
Both electrodes (tool & w/p) should be electrically conductive.
The material to be used as tool electrode should possess desirable
properties like easily machinable, low wear rate, good conductor of
electricity and heat, cheap, and readily available.
Graphite, copper, brass, copper tungsten, cast aluminium, copper
boron, and silver tungsten are some of the materials that are used for
making the tools for EDM. However, copper and graphite are more
commonly used
8. DIELECTRIC SUPPLY SERVO SYSTEM
POWER SUPPLY TOOL & WORKPIECE
ELEMENTS OF EDM
It consists of dielectric fluid, reservoir, filters, pump, and delivery devices.
A good dielectric fluid should possess certain properties, it should:
1.have high dielectric strength (i.e. remain electrically non-conductive
until the required breakdown voltage between the electrodes is attained),
2.take minimum possible time to breakdown (i.e. ignition delay time).
3.deionize the gap immediately after the spark has occurred,
4.serve as an effective cooling medium,
5.have high degree of fluidity.
fluids commonly used as dielectric are transformer oil, paraffin oil,
kerosene, lubricating oils, and deionized water.
9. DIELECTRIC SUPPLY SERVO SYSTEM
POWER SUPPLY TOOL & WORKPIECE
ELEMENTS OF EDM
A servo system is used to maintain a predetermined gap between tool
and workpiece.
There is a gap voltage sensor in power supply, which sends signals to
the servo system.
The servo system will keep the tool reciprocating towards the
workpiece.
Tool wear during EDM also reduces length of tool. For accurate
machining, electrode feeding can be done manually or automatically.
11. Measurement of MRR and / Electrode Wear
MRR is calculated from weight difference of work piece before and after the
performance trial.
MRR = (Wi -Wf)1000/(7.8 t) mm³/min
Where,
Wi = Initial weight of work piece in gms, before trial
Wf = Final weight of Work piece in gms, after trial
t = Period of trials in minutes.
7.8 = Density of steel in gms/cc.
12. The wear of copper electrodes is calculated from the weight difference in electrode weight
before and after the performance trial and is expressed as a percentage of MRR.
Absolute Wear = (Ei - Ef)1000/(8.9 t) mm³/min
Where,
Ei = weight of copper electrode in gm. Before trial
Ef = weight of electrode in gms. After trial
t = Period of trial in minutes.
8.9= Density of cu in gms/ cc.
The wear of graphite electrodes is calculated from the loss in length of electrode during
performance trial,
Absolute Frontal Wear = AL/t mm³/min
Where,
A=frontal area – (mm²)
L =Loss in length of electrode -mm
t = Period of trial in minutes.
Percentage wear=100(Absolute frontal wear) / MRR percentage
13. APPLICATIONS
Drilling of micro holes.
Manufacturing of gears.
Fine holes or slots.
Threat cutting.
Engraving operations.
Rotary form cutting.
Manufacturing of tool having complicated profile.
14. ADVANTAGES
It can produce complex shapes, which otherwise would be
difficult to produce using conventional machining processes.
Tolerance of plus or minus 0.005 can be achieved.
Good surface finish can be obtained economically.
There is no distortion, or vibration of tool or w/p, as there no
physical contact between the tool and workpiece.
Required less machining time.
15. DISADVANTAGES
High power consumption.
Excessive tool wear during machining.
This process is only applicable for metallic or
conductive materials.
Material removal rate or MRR is very slow.
High cost and maintenance cost are required.