Nowadays,necessity of small components is a common trend. These requirements encourage the researcher s to develop very minutest size components to fulfill the demand. The manufact uring of these type of components is a difficult ob ligation and for that various machining methods are develop to manufacture such c omponents. In this article the Electro Chemical mac hining and Electrical Discharge Machining is reviewed. We tried to summar ize the work of various researchers. The study show s that this type of machining processes gives good alternative.
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
An Electrode Shape Configuration on the Performance of Die Sinking Electric D...IJERA Editor
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy
between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of
successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using
different electrode shapes has been carried out. This Research discusses the performance of die sinking EDM due to the
shape configuration of the electrode. The effect of electrode shapes configuration on the performance of die sinking electric
discharge machine has been carried out. The optimization of the parameters of the EDM machining has been carried out by
using the taguchi‟s method for design of experiments (DOE). In this research we have used taguchi‟s method for design of
experiments with three input parameters and their three levels of experiments. The dielectric used is kerosene diluted with
water. The objective of the analysis is to optimize the process parameters of EDM with the help of taguchi method and using
Minitab software.
Study of different work materials effect on surface roughness in electrochemi...eSAT Journals
Abstract In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter-electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is found to be most prominent on Brass work-piece.
Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass; Aluminium; Taguchi; ANOVA.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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.
MULTI RESPONSE OPTIMISATION OF DIE SINKER EDM FOR ALSIC COMPOSITE IAEME Publication
On e of the important aspects that should be taken into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM) is the correct selection of manufacturing conditions. Appropriate choice of the machining parameters and electrode material during electric discharge machining is fundamental to its performance and accuracy.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
An Electrode Shape Configuration on the Performance of Die Sinking Electric D...IJERA Editor
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy
between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of
successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using
different electrode shapes has been carried out. This Research discusses the performance of die sinking EDM due to the
shape configuration of the electrode. The effect of electrode shapes configuration on the performance of die sinking electric
discharge machine has been carried out. The optimization of the parameters of the EDM machining has been carried out by
using the taguchi‟s method for design of experiments (DOE). In this research we have used taguchi‟s method for design of
experiments with three input parameters and their three levels of experiments. The dielectric used is kerosene diluted with
water. The objective of the analysis is to optimize the process parameters of EDM with the help of taguchi method and using
Minitab software.
Study of different work materials effect on surface roughness in electrochemi...eSAT Journals
Abstract In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter-electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is found to be most prominent on Brass work-piece.
Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass; Aluminium; Taguchi; ANOVA.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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.
MULTI RESPONSE OPTIMISATION OF DIE SINKER EDM FOR ALSIC COMPOSITE IAEME Publication
On e of the important aspects that should be taken into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM) is the correct selection of manufacturing conditions. Appropriate choice of the machining parameters and electrode material during electric discharge machining is fundamental to its performance and accuracy.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
EN 1010is a low-carbon steel alloy with 0.10% carbon content. It is known for its fairly low strength and low ductility; however, it can be tempered to increase strength. Machinability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is commonly used for cold headed fasteners, rivets and bolts, in addition to structural, construction and automotive applications such as fenders, pans, nails and transmission covers. Wire Electric Discharge Machine (WEDM) seems to be a good option for machining the complicated profiles. This paper, find effects of various process parameters of Wire EDM such as pulse on time (Ton), pulse off time(Toff), peak current (Ip) and servo voltage (Sv) for analysis of cutting rate (CR) while machining EN 1010. Central Composite Design is used to plan the design of experiment. The output response variable being cutting rate will be measured for all number of experiments conducted. The optimal parameter level combination would be analysed which gives desired cutting rate. These optimized values of different parameters would then be used in execution the machining operation in order to obtain the necessary outputs.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
Electrical discharge machining is a nonconventional machining process which enables machining of complex and intricate shapes, hard materials that are precise and difficult to machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The process involves spark erosion in the presence of dielectric fluid. In this work SCM 420low alloy steel is the material used for the machining purpose with electrolyte copper as tool. This work investigates effect of process parameters peak current (IP), Pulse on time (Ton) and gap voltage (Vg) on Material removal rate (MRR) and surface roughness (Ra). Response surface methodology is used for experimental design. The suggested model can be used in the different manufacturing firms by selecting right combination of process parameters to achieve optimal values of output responses.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF MATERIAL EN-31 IN...ijiert bestjournal
The paper represent the work done for making mathematical models fo r analysis of the effects of machining parameters on the performance characteristics in EDM process of Alloy steel (EN-31). The mathematical models are developed using the response surface methodology (RSM) to explai n the influences of machining parameters on the performance characteristics in the EDM process.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
EN 1010is a low-carbon steel alloy with 0.10% carbon content. It is known for its fairly low strength and low ductility; however, it can be tempered to increase strength. Machinability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is commonly used for cold headed fasteners, rivets and bolts, in addition to structural, construction and automotive applications such as fenders, pans, nails and transmission covers. Wire Electric Discharge Machine (WEDM) seems to be a good option for machining the complicated profiles. This paper, find effects of various process parameters of Wire EDM such as pulse on time (Ton), pulse off time(Toff), peak current (Ip) and servo voltage (Sv) for analysis of cutting rate (CR) while machining EN 1010. Central Composite Design is used to plan the design of experiment. The output response variable being cutting rate will be measured for all number of experiments conducted. The optimal parameter level combination would be analysed which gives desired cutting rate. These optimized values of different parameters would then be used in execution the machining operation in order to obtain the necessary outputs.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
Electrical discharge machining is a nonconventional machining process which enables machining of complex and intricate shapes, hard materials that are precise and difficult to machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The process involves spark erosion in the presence of dielectric fluid. In this work SCM 420low alloy steel is the material used for the machining purpose with electrolyte copper as tool. This work investigates effect of process parameters peak current (IP), Pulse on time (Ton) and gap voltage (Vg) on Material removal rate (MRR) and surface roughness (Ra). Response surface methodology is used for experimental design. The suggested model can be used in the different manufacturing firms by selecting right combination of process parameters to achieve optimal values of output responses.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF MATERIAL EN-31 IN...ijiert bestjournal
The paper represent the work done for making mathematical models fo r analysis of the effects of machining parameters on the performance characteristics in EDM process of Alloy steel (EN-31). The mathematical models are developed using the response surface methodology (RSM) to explai n the influences of machining parameters on the performance characteristics in the EDM process.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
Modeling and Analysis of process parameters on Surface Roughness in EDM of AI...Mohan Kumar Pradhan
Response Surface Methodology (RSM)
is used to investigate the effect of four controllable input variables
namely: discharge current, pulse duration, pulse off time and applied
voltage Surface Roughness (SR) of on Electrical Discharge Machined
surface. To study the proposed second-order polynomial model for
SR, a Central Composite Design (CCD) is used to estimation the
model coefficients of the four input factors, which are alleged to
influence the SR in Electrical Discharge Machining (EDM) process.
Experiments were conducted on AISI D2 tool steel with copper
electrode. The response is modeled using RSM on experimental
data. The significant coefficients are obtained by performing Analysis
of Variance (ANOVA) at 5% level of significance. It is found that
discharge current, pulse duration, and pulse off time and few of their
interactions have significant effect on the SR. The model sufficiency
is very satisfactory as the Coefficient of Determination (R2) is found
to be 91.7% and adjusted R2-statistic (R2
adj) 89.6%.
Influence of process parameters on MRR in EDM of AISI D2 Steel: a RSM approachMohan Kumar Pradhan
Response Surface Methodology (RSM) is used to investigate the
effect of three controllable input variables namely: discharge current, pulse duration,
and pulse off time on material removal rate (MRR) in EDM process. To study the
proposed second-order polynomial model for MRR, a central composite design is
used to estimation the model coefficients of the three factors, which are believed to
influence the MRR in EDM process. Experiments were conducted on AISI D2 tool
steel with copper electrode. The response is modeled using RSM on the experimental
data. The significant coefficients are obtained by performing analysis of variance
(ANOVA) at 5% level of significance. It is found that discharge current, pulse duration,
and pulse off time and few of their interactions have significant effect on the MRR.
The model sufficiency is very satisfactory as the coefficient of determination (R2) is
found to be 97.6%.
MODELING AND OPTIMIZATION OF EDM PROCESS PARAMETERS: A REVIEWIAEME Publication
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermo electric energy between the work piece and an electrode. There are different input parameters which influence on the outputs such as MRR, TWR and SR.
Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, which is an essential need for industries towards manufacturing of quality products at lower cost.
MULTI OBJECTIVE OPTIMIZATION OF NEAR-DRY EDM PROCESS USING RESPONSE SURFACE M...IAEME Publication
The correct selection of manufacturing technique is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). It is capable of machining geometrically complex or hard
material components, which are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
Similar to ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICROMACHINING METHODS-A REVIEW (20)
Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
A COMPARATIVE STUDY OF DESIGN OF SIMPLE SPUR GEAR TRAIN AND HELICAL GEAR TRAI...ijiert bestjournal
In recent times,the gear design has become a highl y complicated and comprehensive subject. A designer of modern gear drive system must have to r emember that the main objective of gear drive is to transmit higher power with comparatively smaller overall dim ensions of the driving system which can be construc ted with minimum possible manufacturing cost,runs reas onably free of noise and vibration and which requir es little maintenance. In this paper single stage spur gear t rain and helical gear train with a idler gear are d esigned by American Gear Manufacturing Association (AGMA) stan dard. A idler gear is placed between two gearwheel to obtained the same direction of rotation. AGMA stres s equation is used to determined the tooth bending strength and surface contact strength. As a result,dimensio ns of gears are find out and comparative study is c arried out to select the optimum design of gear train for a give n input parameter
COMPARATIVE ANALYSIS OF CONVENTIONAL LEAF SPRING AND COMPOSITE LEAFijiert bestjournal
A leaf spring is a simple form of spring,commonly used for the suspension in wheeled vehicles. It is also one of the oldest forms of spring. Sometimes referred to as a semielliptical l eaf spring (SELS) it takes the form of a slender ar c-shaped length of spring steel of rectangular cross section. The centre of the arc p rovides location for the axle,while tie holes are provided at either end for attaching to the vehicle body. In the present work,a seven-leaf steel spring use d in passenger cars is replaced with a composite mu lti leaf spring made of glass/epoxy composites. The dimensions sand the num ber of leaves for both steel leaf spring and compos ite leaf springs are considered to be the same. The primary objective is to compare their load carrying capacity,stiffness and weight savings of composite leaf spring. Finally,fatigue life of steel and com posite leaf spring is also predicted using life dat a
Brimmed diffuser is collection�acceleration device which shrouds a wind turbine.For a given turbine di ameter,the power augmentation can be achieved by brimmed diffuser,p opularly known as wind lens. The present numerical investigation deals with the effect of low pressure region created by wind l ens and hence to analyze the strong vortices formed by a brim attached to the shroud diffuser at exit. Also in this analysis,a c omparative numerical prediction of mass flow rates through the wind turbine has been carried out with various types of wind lens wh ich in turn helps to optimize the torque augmentati on. It has been numerically proved that there is significant increase in the wa ke formation & vortex strength when brimming effect is added to a diffuser
FINITE ELEMENT ANALYSIS OF CONNECTING ROD OF MG-ALLOY ijiert bestjournal
The automobile engine connecting rod is a high volume production,critical component. It co nnects reciprocating piston to rotating crankshaft,transmitting the thrust of the piston to the crankshaft. Every vehicle that uses an internal combustion engine requires at least one connecting rod depending upon the number of cylinders in the engine. As the purp ose of the connecting rod is to transfer the reciprocating motion of the piston into rotary motion of the crankshaft. Connecting ro ds for automotive applications are typically manufactured by forging from either w rought steel or powdered metal. the material used f or this process is Mg-Alloy and also finite element analysis of connecting rod
REVIEW ON CRITICAL SPEED IMPROVEMENT IN SINGLE CYLINDER ENGINE VALVE TRAINijiert bestjournal
The purpose of valve train is to operate the inlet and outlet valves of the engine. The valve train m ainly consists of rocker arm,push rod,cam,poppet valve and spring for kee p the valves closed position. The Greaves G400WG en gine valve train is operated at the maximum speed of 3600 rpm. The main objective of this project is to improve the valve train speed up to safe speed limit that is up to 5000 rpm. The valve spring parameters are optimized based on space availability,stress limit,stiffness,buckl ing of pushrod and natural frequency of the system. The optimized valv e spring configuration is used in the push rod type valve train and the valve train dynamics for different engine speed is studie d using commercially available multi-body dynamic A DMAS software. A comparative valve train dynamics analysis is also c arried out with the existing and optimized valve sp ring combinations. It is observed that valve jump engine speed with respect to optimized valve spring is enhanced to considerab le amount when compared to the existing valve spring configuration. Design improvements include detail study on following topi cs:1. Valve Spring Stiffness. 2. Push rod buckling. 3. Valve closing Velocity. 4. Contact stress between cam and follower
ENERGY CONVERSION PHENOMENON IN IMPLEMENTATION OF WATER LIFTING BY USING PEND...ijiert bestjournal
This paper consist of working of reciprocating pump which is driven by a compound pendulum. It provide s the energy required to lift the water from a tank placed approximately several meter below the ground level. Basic application of the mechanism will be for watering the garden which will be operated by means of operation opening and closing of entrance gate. Paper consists of basic concept,design of pump and compound pendulum mecha nism and fabricationed model. The concept can also be implemented in the rural areas,having the problem of electric supply. We aim at making a prototype for providing some me an for pumping of water by the pump which requires less human efforts,conside ring cost effectiveness,easy to operate and portab le mechanism.
The IC engine has seen numerous revolutionary and e volutionary modifications in technology and design over the past few decades. The sole motto behind the modifications wa s to increase the overall efficiency of the IC Engi ne including volumetric and thermal efficiency. Recently few benchmarking techn ologies like the CRDI,MPFI,HCCI,etc. in the Otto cycle and Diesel cycle engines have created an enormous revolution in the automobile industry. In spite of these technologica l and design advances,the efficiencies are not being more than a particular l imit. However,the concept of split cycle engines has dra stically increased the overall performance in all respect. The split cycle concept basically separates the fou r strokes of the conventional cycle. The Scuderi engine one of the best-in-class engine desi gns based on the split cycle concept. The Scuderi engine works on the split cycle and gives higher efficiency than the previous split cycle engines resulting overall high perform ance. It also eliminates the problems faced by previous engines based on the spl it cycle in terms of breathing (volumetric efficien cy) and thermal efficiency. This paper throws light on the greater volumetric,thermal and overall efficiency key points related t o the Scuderi Engines.
EXPERIMENTAL EVALUATION OF TEMPERATURE DISTRIBUTION IN JOURNAL BEARING OPERAT...ijiert bestjournal
The excessive rise of temperature in the journal be aring operating at boundary/mixed lubrication regim es. Journal bearing test set- up is used to measure the temperature along the cir cumference of the bearing specimen for different lo ading conditions. Here in this journal bearing of l/d ratio 1,diameter of jo urnal is 60mm and the bearing length is 60mm,clear ance is .06mm has been designed and tested to access the temperature rise of the bearing. The result shows that as the load o n the bearing is increasing temperature also increasing. Temperature analysis o f journal bearing is also done by the Ansys workben ch software
STUDY OF SOLAR THERMAL CAVITY RECEIVER FOR PARABOLIC CONCENTRATING COLLECTOR ijiert bestjournal
Energy is one of the building blocks of the country . The growth of the country has been fueled by chea p,abundant energy resources. Solar energy is a form of renewable ener gy which is available abundantly and collected unre servedly. The parabolic concentrator reflects the direct incident solar rad iation onto a receiver mounted above the dish at it s focal point. The conversion of concentrated solar radiation to heat takes place in receiver. The heat transfer characteristics of the receiver changes during the rotation of the receiver which affects thermal performance. The working temperature may also influence the ther mal performance and overall efficiency of the system. Thermal as well as optica l losses affect the performance of a solar paraboli c dish-cavity receiver system. The thermal losses of a solar cavity receiver include c onvective and radiative losses to the air in the ca vity and conductive heat loss through the insulation used behind the helical tube surface. Convective and radiative heat losses form the major constituents of the thermal losses. The convection heat loss from cavit y receiver in parabolic dish solar thermal power sy stem can significantly reduce the efficiency and consequently the cost effectiveness of the system. It is important to assess this heat loss and subsequently improve the thermal performance of the receiver.
DESIGN, OPTIMIZATION AND FINITE ELEMENT ANALYSIS OF CRANKSHAFTijiert bestjournal
Crankshaft is a crucial component in an engine asse mbly. Crankshaft is consisting of two web sections and one crankpin,which converts the reciprocating displacement of the pist on to a rotary motion with a four link mechanism. G enerally crankshafts are manufactured using cast iron and forged steel mater ial. In this work to design and finite element anal ysis of crankshaft of 4 cylinder petrol engine of Maruti swift Vxi. of 1200 cubic capacity. The finite element analysis in ABA QUS software by using six materials based on their composition viz. Cast iron,EN30B,SAE4340,Structural steel,C70 Alloy steel and Aluminium based composite material reinforced with silicon carbide & fly ash. The parameter like von misses stress,deformation;maximum and minimum principal stress & strain were obtained from analysis software. The results of Finite element show that t he Aluminium based composite material is best mater ial among all. Compare the result like weight and Stiffness parameter. It is resulted of 65.539 % of weight,with reduction i n deformation.
HEAT TRANSFER ENHANCEMENT BY USING NANOFLUID JET IMPINGEMENTijiert bestjournal
An experimental investigation was carried out for s tudying the heat transfer performance of the water-Al2O3 (28nm average particle size) nanofluid inside a liquid evacuated impinging jet system dest ined to the cooling of circular target surface. Results have shown that th e surface heat transfer coefficient increases consi derably when the mass flow rate is increased,but is relatively insensitive to the nozzle-to heated-surface distance. It was foun d that the use of a nanofluid can provide a heat transfer enhancement when compared t o water. Thus most practical applications of jet im pingement occur in industries where the heat transfer requirements hav e exceeded capacity of ordinary heating and cooling techniques. This work presents and discusses the results of an experiment al investigation of heat transfer between the horiz ontal smooth plate of impinged jets.
MODIFICATION AND OPTIMIZATION IN STEEL SANDWICH PANELS USING ANSYS WORKBENCH ijiert bestjournal
The demand for bigger,faster and lighter moving ve hicles,such as ships,trains,trucks and buses has increased the importance of efficient str uctural arrangements. In principle two approaches exist to develop efficient structures:e ither application of new materials or the use of new structural design. A proven and well-establi shed solution is the use of composite materials and sandwich structures. In this way high strength to weight ratio and minimum weight can be obtained. The sandwich structures have potential to offer a w ide range of attractive design solutions. In addition to the obtained weight reduction,these so lutions can often bring space savings,fire resistance,noise control and improved heating and cooling performance. Laser-welded metallic sandwich panels offer a number of outstand ing properties allowing the designer to develop light and efficient structural configuratio ns for a large variety of applications. These panels have been under active investigations during the last 15 years in the world.
IMPACT ANALYSIS OF ALUMINUM HONEYCOMB SANDWICH PANEL BUMPER BEAM: A REVIEW ijiert bestjournal
Bumper is a energy absorbing protective element whi ch absorb the energy in front collision and protect valuable parts like radiator etc. Bumper is act like protect ive shield generally made of steel material. As eco nomic point of view and to reduce consumption of fuel manufacturin g of light weight vehicle is requirement of current situation. Application of composite material in automobile sec tor is now day common thing. Aluminum honeycomb san dwich panel is basically material from aerospace industri es and known for its high strength to weight ratio. Sandwich structure basically having its properties due to ge ometry. To determine various properties of sandwich structure conducting experiments is expensive,so generally F EA is used .However complex geometry is hurdle so t here are various theories are available for simplification o f model. These theories convert 3D model in to homo genous model .As far as concerning India manufacturing rate of s andwich structure is very less,so generally cost i s more. Greatest giant manufacturer is china we can observe their bu llet train and metro transport facility constructio n. Recently in march 2014 largest selling Indian cars are failed in NCap test in 100% frontal crash test. So requirement of more energy absorbing material with economy cons ideration is important.
Robotic welding requires specialized fixtures to ac curately hold the work piece during the welding operation. Despite the large variety of welding fix tures available today the focus has shifted in maki ng the welding arms more versatile,not the fixture. T he new fixture design reduces cycle time and operat or labor while increasing functionality;and allows co mplex welding operations to be completed on simple two axis welding arms
ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...ijiert bestjournal
In these paper structural fields of the solid disc brake during short and emergency braking with four different materials is studied. The distribution of the tempe rature depends on the various factors such as frict ion,surface roughness and speed. The effect of the angular velo city and the contact pressure induces the temperatu re rise of disc brake. The finite element simulation for three -dimensional model was preferred due to the heat fl ux ratio constantly distributed in circumferential direction . Here value of temperature,friction contact power,nodal displacement and deformation for different pressure condition using analysis software with four materi als namely cast iron,cast steel,aluminium and carbon fibre reinforced plastic are taken. Presently the D isc brakes are made up of cast iron and cast steel. With the v alue of simulation result best suitable material fo r the brake drum with higher life span is determined.
REVIEW ON MECHANICAL PROPERTIES OF NON-ASBESTOS COMPOSITE MATERIAL USED IN BR...ijiert bestjournal
Metallic matrix composites are combinations of two or more different metals inter metallic compounds or second phases in which dispersed phases are embe dded within the metallic matrix. They are produced by controlling the morphologies of the constituents to achieve optimum combination of properties. Properties of the composites depend on the properti es of the constituent phases,their relative amount,and dispersed phase geometry including particle siz e,shape and orientation in the matrix. In this pap er,The mechanical properties,behaviour and micro stru ctural evolution of aluminium metal matrix metallic composites fabricated under various process conditi ons were investigated to understand their process- structure�property relations by optimization proces s. Addition of silicon carbide to aluminum has show n an increase in its mechanical properties.
PERFORMANCE EVALUATION OF TRIBOLOGICAL PROPERTIES OF COTTON SEED OIL FOR MULT...ijiert bestjournal
A lubricant is a substance that reduces friction an d wear by providing a protective film between two moving surfaces. Good lubricants possess the proper ties such as low toxicity,high viscosity index,hi gh load carrying capacity,excellent coefficient of fr iction,good anti-wear capability,low emission int o the environment,high ignition temperature. So tribolog y related problems can be minimized by proper selection of lubricant from wear consideration. Tod ay,the depletion of reserves of crude oil,the gro wing prices of crude oil and concern about protecting th e environment against pollution have developed the interest towards environment-friendly lubricants. B ecause of these the purpose of this work is to eval uate the anti-wear characteristics of cottonseed oil and to check the suitability of cottonseed oil as a lu bricant for multi-cylinder engine. Four ball testing machin e is used for anti-wear testing as per ASTM D 4172. The wear preventive characteristic of cottonseed oi l is obtained by measuring wear scar diameter. The present study shows the potential of cotton seed oi l as an alternating lubricant.
Magnetic abrasive finishing is a machining process where the tooling allowance is remove by media wi th both magnetic and abrasive properties,with a magnetic f ield acting as a binder of a grain. Such machining falls into the category of erosion by abrasive suspension and lend itself to the finishing of any type of surface . The possibility of finishing complex surfaces is a spec ial benefit of this machining. Magnetic abrasive fi nishing process is most suitable for obtaining quality fini sh on metallic and non-metallic surfaces. Magnetic abrasive finishing used for complicated product finishing & Roughness and tolerance band achieved that is diffi cult using conventional machine process. The product dimension al requirement easily possible with taking trial wi th MAF parameters.
DESIGN OF INNER LID OF PRESSURE COOKER WITH CIRCULAR SHAPE HAVING STRAIGHT ED...ijiert bestjournal
Pressure cooker works hand in hand with the workin g woman. This is happening because of saving in tim e & energy. It means that pressure cooker become the in evitable item in kitchen. If we concentrate on the analysis of inner lid of the pressure cooker,it is highly bene ficial for everyone. That is why we concentrate on the possible shapes of lids of pressure cooker. The existing pre ssure cooker is of two type i. e. inner lid and out er lid type. The shape of existing inner lid pressure cooker is gene rally having elliptical shape. This shape is becaus e of locking & easy handling. The different alternatives are arisi ng. Out of which the best alternative found is the circular shape having straight edges at the edges. The modificatio n suggested here is also serving the same purposes as like the previous one. The advantages obtained here are also giving better result for locking,increase the hea t transfer area & saving in cooling time for food in measurable way as compare with the elliptical inner lid pressure c ooker. The result obtained will be definitely good comparing w ith the old model. Here simple & thermal stress ana lysis had been done by finite element method for the load & t emperature stability.
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
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.
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.
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.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICROMACHINING METHODS-A REVIEW
1. Novateur Publication’s
International Journal of Innovation in Engineering, Research and Technology [IJIERT]
ICITDCEME’15 Conference Proceedings
ISSN No - 2394-3696
1 | P a g e
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE
MACHINING PROCESSES MICROMACHINING METHODS-A REVIEW
Shantanu Kale
PG student, Department of Mechanical Engineering, PCCOE, Pune, India.
Prasad Unde
PG student, Department of Mechanical Engineering, MIT, Aurangabad, India.
Subhash Khamkar
PG student, Department of Mechanical Engineering, PDVVP, Ahmednagar, India.
ABSTRACT
Nowadays, necessity of small components is a common trend. These requirements encourage the researchers to develop very minutest
size components to fulfill the demand. The manufacturing of these type of components is a difficult obligation and for that various
machining methods are develop to manufacture such components. In this article the Electro Chemical machining and Electrical
Discharge Machining is reviewed. We tried to summarize the work of various researchers. The study shows that this type of
machining processes gives good alternative.
KEYWORDS: Electro Chemical Machining, Electrical Discharge Machining.
INTRODUCTION
The automotive, aerospace, electronics, optics, medical devices and communications industries always demand for the macro and
micro components. Generally these components are made up of difficult-to–machine materials such as tool steel, carbides, super
alloys and titanium alloys. The machining of these type of components need to develop new machining methods as the machining of
these type of materials is not possible or economical with conventional methods. Two methods Electrical Discharge Machining
(EDM) and Electrochemical Machining (ECM) offer a better nonconventional method for these materials. This paper presents a brief
review of the state-of-the art research and developments in modeling, surface integrity, monitoring and control, tool material and tool
wear and hybrid processes.
Sharifa S. et al .investigate the influence of Electrical Discharge Machining (EDM) input parameters on characteristics of EDM
process. Stainless steel 3161 and copper imbued graphite which is used as electrode is considered for this study. The 2levels of full
factorial method in design of experiments is used to carry out the test. In this study the Analysis of variance (ANOVA) and
mathematical modeling were established for the process and material related parameters like material removal rate (MRR), electrode
wear rate (EWR), surface roughness (SR) and dimensional accuracy (DA).The first order model is required to fit dimensional
accuracy linear model. However, second order model are required to fit MRR,EWR and SR quadratic models respectively. The result
shows that the peak current was the most significant factors to all variable responses. Based on confirmation run, all the results are less
than 15% error, thus, indicating the model that were developed for MRR, SR, EWR and Dimensional Accuracy are reasonable
accurate. The experimentation is performed on Sodick AM3L die sinking EDM machine. Copper imbued graphite (EDM-C3) was
chosen as the electrode and stainless steel 316l as the workpiece material. The process parameters selected were peak current, servo
voltage pulse ON-OFF time.
The depth of machining was set to 3mm and the machining time is recorded. The result of study shows that the peak current, pulse on
time and pulse off time are significant factors. Whereas the servo voltage does not have significant effects to the machining. The
authors made some recommendation to get better results as the depth of cut should set at least 5mm instead of 3mm prior, to get more
specific data for electrode weight. Also Workpiece surface integrity such as recast layer, heat affected zone (HAZ), microstructure and
micro cracks should be investigated also for better understanding of EDM phenomenon. The future scope of the study to investigate
the parameters like jet flushing, dielectric fluid.
Das M.K. et al .carry out the investigation of conductive difficult to machine material like super alloys, Ti-alloys, alloy steel, tool
steel, stainless steel, etc. The investigating parameters for this study are the material removal rate (MRR) and surface roughness
2. Novateur Publication’s
International Journal of Innovation in Engineering, Research and Technology [IJIERT]
ICITDCEME’15 Conference Proceedings
ISSN No - 2394-3696
2 | P a g e
characteristic. Use of optimal ECM process parameters can significantly reduce the ECM operating, tooling, and maintenance cost and
will produce components with higher accuracy. Milan Kumar Das et al. studies the effect and parametric optimization of process
parameters in ECM of EN31 tool steel using grey relation analysis. Experiments are conducted based on Taguchi’s L27
orthogonal
array (OA) with four process parameters like electrolyte concentration, voltage, feed rate and inter-electrode gap. ANOVA is
performed to get the contribution of each parameter on the performance characteristics. Experiments are conducted on the
METATECH (ECMAC) electrochemical machining equipment. Rectangular block of 20mm X 20mm and 25 mm height made of
EN31 tool steel which is a high carbon alloy steel with high degree of hardness, compressive strength and abrasion resistance is
chosen as work-piece. They conclude that lowest level of electrolyte concentration, mid-level of voltage, mid-level of feed rate and the
lowest level of electrode gap gives the better results. ANOVA reveals that electrolyte concentration has the maximum influence on
metal removal rate and surface roughness characteristics. Authors reported that the electrolyte concentration is the significant process
parameter. The optimal combination is electrolyte concentration 10%, voltage 10 V, feed rate 0.25 mm/min and inter-electrode gap
0.2 mm for maximum MRR and minimum surface roughness.
Rajurkar K.P. et al. reviews the Electrochemical and electro-discharge machining processes. They stated that the EDM and ECM are
the only alternatives for manufacturing the complex 3D shapes and micromachining. Authors studied both the processes briefly and
commented about the advantages, the applications and the research related to the processes. They summaries the work by mentioning
that ECM and EDM technologies have been successfully adapted to produce macro, micro components with complex features and
high aspect ratios for biomedical and other applications. These processes are also being attempted at the nano-scale.
Cardoso P. et al. Reviewed the micromachining processes as the demand for minimized components with high aspect ratios and
superior surfaces is more now a days. Generally these type of components are generated from metals, polymers, composites and
ceramics. Authors particularly concentrate on micro milling. The most significant inputs in the micromachining process are related to
the tools, machine tools and, not least importantly, machining parameters. Also the study related with micromachining are the
minimum chip thickness and size effect, the cutting temperatures and cutting forces, which influence the tool wear and its failure,
which, in turn, influence the burr formation and, consequently, surface quality is carried out.
Saravanan1D. et al. In this paper, authors try to find out the optimum machining parameters for machining Super Duplex Stainless
Steel using ECMM. For this purpose Taguchi L18 orthogonal array is used to find the influencing machining parameters on Material
Removal Rate (MRR).Authors reported that the duty cycle is the most significant parameter in deciding the MRR. More the duty
cycle, more is the MRR. Authors concluded their work by identifying the duty cycle as the most significant process parameter. They
also mentioned that the influence of electrolyte concentration, voltage and current also depends on the duty cycle.
SUMMARY
In this paper current developments in various aspects of electrochemical and electro-discharge machining is presented in this paper.
ECM and EDM technologies have been successfully adapted to produce macro, micro components with complex features and high
aspect ratios for biomedical and other applications. These processes are also being tried at the nano-scale.
REFERENCES
[1] Sharifa S., Safieia W., Mansorb A.F., Isac M.H.and Saada R.M. (2015).Experimental study of electrical discharge machine (die
sinking) onstainless steel 316L using design of experiment. Procedia Manufacturing 2,147 – 152.
[2] Das M.K., Kumarb K., Barmana T.K.and Sahooa P. (2014).Optimization of Surface Roughness and MRR in Electrochemical
Machining of EN31 Tool Steel using Grey-Taguchi Approach. Procedia Materials Science 6,729 – 740.
[3] Rajurkara K.P., Sundaramb M.M. and Malshec A.P. (2013).Review of Electrochemical and Electro discharge Machining.
Procedia CIRP 6, 13 – 26.
[4] Cardoso P. and Davim J.P.(2012). A brief review on micromachining of materials.Rev.Adv.Mater. Sci. 30, 98-102.
[5]Saravanan D., Arularasu M.and Ganesan K. (2012).A study on electrochemical micromachining of super duplex stainless steel for
biomedical filters.ARPN journal of engineering and applied sciences. Vol. 7, no. 5,517-523.