This document discusses predicting optimized EDM machining parameters through thermo-mechanical analysis. It begins with an abstract that outlines the goal of determining optimal machining parameters to maximize material removal rate in EDM of OHNS die steel. It then reviews relevant literature on thermal modeling and optimization of EDM processes. The problem statement indicates the challenges of determining optimal pulse duration, peak current, and voltage to increase material removal rate cost-effectively. The objectives are presented as determining parameters to maximize material removal rate and improve surface integrity of machined workpieces. Finally, the theoretical analysis section outlines the numerical modeling approach using finite element analysis and Joshi and Pande's thermal model of EDM sparks.
This document describes an experimental study that evaluated the material stability of different aluminum alloys for ultra precision applications. Specifically, it tested 7075-T7351, 7075-T6 and 6061-T6 aluminum alloys under cyclic loading conditions. The study used a custom test machine with sensors to precisely measure deformation in the aluminum alloy samples. Results showed that the different alloys exhibited inelastic and plastic deformation under loading and unloading cycles. Inelastic deformation recovered after unloading, while plastic deformation remained. The document aims to determine the most suitable aluminum alloy to replace steel components in high frequency weighing scales.
This document discusses using a back propagation neural network (BPNN) to predict carbon monoxide (CO) emissions from a diesel engine. It begins by providing background on BPNN and how it was applied in this study. Experimental data on engine parameters and CO emissions were collected from tests. The data were divided into training and testing sets to train and validate the BPNN. Different combinations of engine parameters were used as inputs to the BPNN in various "strategies" to determine the best parameters for accurately predicting CO emissions. The BPNN architecture and training parameters were optimized to minimize error between predicted and actual CO emissions. The goal was to develop a method for predicting emissions to better control engine parameters and reduce pollution.
- The document discusses the use of finite element analysis to model thermal barrier coatings on diesel engine pistons. Thermal barrier coatings can increase piston performance by reducing surface temperatures.
- The analysis compared coated pistons made of AlSi alloy and steel. It found that coating both materials reduced maximum surface temperatures, by 28% for AlSi and 17% for steel.
- Finite element modeling is useful for virtually prototyping thermal barrier coating systems and analyzing how coating thickness, material properties, stresses, and boundary conditions impact temperature distribution.
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.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
This document summarizes research that used response surface methodology to optimize the electrical discharge machining (EDM) process parameters when machining SCM420 low alloy steel. The researchers investigated the effects of peak current, pulse on time, and gap voltage on material removal rate (MRR) and surface roughness (Ra). They conducted experiments according to a central composite design and analyzed the results to develop mathematical models relating the process parameters to the output responses. The analysis found that peak current had the greatest influence on both MRR and Ra, with MRR increasing and Ra decreasing at higher peak current levels. Optimal values for the process parameters to achieve high MRR and low Ra were determined to be a peak current of 22 amps, pulse
The use of ekf to estimate the transient thermal behaviour of induction motor...Mellah Hacene
This document summarizes a journal article that examines using an Extended Kalman Filter (EKF) to estimate the transient thermal behavior of an induction motor drive without sensors. It first reviews common thermal modeling methods for induction motors, including simple, finite element, and electrical equivalent circuit models. It then presents the authors' thermal model of the induction motor in state-space form, incorporating linear relationships between resistance and temperature, power losses, heat transfer, and temperature rise in the stator and rotor. The resulting state equations can be used by the EKF for sensorless estimation of temperatures and resistances.
This document provides a review of recent developments in electrochemical machining (ECM) and electrical discharge machining (EDM). ECM and EDM are important machining processes that can machine difficult materials like metals, alloys, and composites. The document summarizes advances in modeling and simulation of ECM processes, process monitoring and control techniques, machining capabilities including high aspect ratio microstructures, use of different electrolytes, and development of microtools. It also briefly discusses emerging areas like nano-electro machining and hybrid processes combining ECM with other techniques.
Optimization of process parameters on edm of ti 6 al-4v- materials today paperDr. Bhiksha Gugulothu
This document discusses optimizing process parameters for electrical discharge machining (EDM) of titanium alloy Ti-6Al-4V. Experiments were conducted using Taguchi's L27 orthogonal array to investigate the effects of discharge current, pulse on time, pulse off time, and dielectric fluid on material removal rate and surface roughness. Drinking water provided the highest material removal rate and lowest surface roughness. Analysis of variance showed that discharge current had the greatest influence on material removal rate, followed by pulse on time, while dielectric fluid and discharge current most influenced surface roughness. The maximum material removal rate and minimum surface roughness obtained were 5.46 mm3/min and 2.53 μm respectively using optimized parameters.
This document describes an experimental study that evaluated the material stability of different aluminum alloys for ultra precision applications. Specifically, it tested 7075-T7351, 7075-T6 and 6061-T6 aluminum alloys under cyclic loading conditions. The study used a custom test machine with sensors to precisely measure deformation in the aluminum alloy samples. Results showed that the different alloys exhibited inelastic and plastic deformation under loading and unloading cycles. Inelastic deformation recovered after unloading, while plastic deformation remained. The document aims to determine the most suitable aluminum alloy to replace steel components in high frequency weighing scales.
This document discusses using a back propagation neural network (BPNN) to predict carbon monoxide (CO) emissions from a diesel engine. It begins by providing background on BPNN and how it was applied in this study. Experimental data on engine parameters and CO emissions were collected from tests. The data were divided into training and testing sets to train and validate the BPNN. Different combinations of engine parameters were used as inputs to the BPNN in various "strategies" to determine the best parameters for accurately predicting CO emissions. The BPNN architecture and training parameters were optimized to minimize error between predicted and actual CO emissions. The goal was to develop a method for predicting emissions to better control engine parameters and reduce pollution.
- The document discusses the use of finite element analysis to model thermal barrier coatings on diesel engine pistons. Thermal barrier coatings can increase piston performance by reducing surface temperatures.
- The analysis compared coated pistons made of AlSi alloy and steel. It found that coating both materials reduced maximum surface temperatures, by 28% for AlSi and 17% for steel.
- Finite element modeling is useful for virtually prototyping thermal barrier coating systems and analyzing how coating thickness, material properties, stresses, and boundary conditions impact temperature distribution.
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.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
This document summarizes research that used response surface methodology to optimize the electrical discharge machining (EDM) process parameters when machining SCM420 low alloy steel. The researchers investigated the effects of peak current, pulse on time, and gap voltage on material removal rate (MRR) and surface roughness (Ra). They conducted experiments according to a central composite design and analyzed the results to develop mathematical models relating the process parameters to the output responses. The analysis found that peak current had the greatest influence on both MRR and Ra, with MRR increasing and Ra decreasing at higher peak current levels. Optimal values for the process parameters to achieve high MRR and low Ra were determined to be a peak current of 22 amps, pulse
The use of ekf to estimate the transient thermal behaviour of induction motor...Mellah Hacene
This document summarizes a journal article that examines using an Extended Kalman Filter (EKF) to estimate the transient thermal behavior of an induction motor drive without sensors. It first reviews common thermal modeling methods for induction motors, including simple, finite element, and electrical equivalent circuit models. It then presents the authors' thermal model of the induction motor in state-space form, incorporating linear relationships between resistance and temperature, power losses, heat transfer, and temperature rise in the stator and rotor. The resulting state equations can be used by the EKF for sensorless estimation of temperatures and resistances.
This document provides a review of recent developments in electrochemical machining (ECM) and electrical discharge machining (EDM). ECM and EDM are important machining processes that can machine difficult materials like metals, alloys, and composites. The document summarizes advances in modeling and simulation of ECM processes, process monitoring and control techniques, machining capabilities including high aspect ratio microstructures, use of different electrolytes, and development of microtools. It also briefly discusses emerging areas like nano-electro machining and hybrid processes combining ECM with other techniques.
Optimization of process parameters on edm of ti 6 al-4v- materials today paperDr. Bhiksha Gugulothu
This document discusses optimizing process parameters for electrical discharge machining (EDM) of titanium alloy Ti-6Al-4V. Experiments were conducted using Taguchi's L27 orthogonal array to investigate the effects of discharge current, pulse on time, pulse off time, and dielectric fluid on material removal rate and surface roughness. Drinking water provided the highest material removal rate and lowest surface roughness. Analysis of variance showed that discharge current had the greatest influence on material removal rate, followed by pulse on time, while dielectric fluid and discharge current most influenced surface roughness. The maximum material removal rate and minimum surface roughness obtained were 5.46 mm3/min and 2.53 μm respectively using optimized parameters.
A Study on Stochastic Thermal Characterization of Electronic PackagesIJERA Editor
Insofar as the electronics can be found now in several applications of multiple domains, we have tried to
highlight in this study that, those systems must be based on unquestionable reliability and meet the needs of the
external environment. Starting from the unit "°c / w" concerning the thermal resistance from the gap between
junction temperature and a reference temperature, we have tried to compare the thermal performance of
electronic packages taking into consideration the thermal management. Our approach is based on the Monte
Carlo simulation and the stochastic characterization of the QFN. From the norm of normalization, we have
obtained standardized data sheets allowing accurate comparisons of the thermal performance of electronic
packages as produced by different manufacturers. Our numerical model through simulation, prototyping
concerning the design involves the JEDEC recommendations, which we consider a very interesting alternative.
Through the deterministic analysis, we conducted an analysis from the Matlab program parameters, which
control the Ansys software, the results were processed by statistical techniques to evaluate the times of the
thermal resistance of the QFN. That is why we must consider the electronic package (encapsulating the
integrated circuit), through the printed circuit board (PCB) to ensure the junction temperature maintenance and
avoid the dissipation of the heat. Also our process was based on the union of the finite element method to the
Monte Carlo simulation and stochastic characterization of the QFN.
Keywords: Electronic package; Finite element method; printed
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
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.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
IRJET- Experimental Analysis for Thermal Performance of Muffler Guard Hero Xt...IRJET Journal
This document summarizes an experimental analysis of the thermal performance of a muffler guard for a Hero XTREME 200R motorcycle. The study designs and models a basic and modified muffler guard using CAD software. Temperature measurements are taken at points on the basic and modified guards under idling and running engine conditions using an infrared thermometer. Graphs of the temperature data show the modified guard with vertical and horizontal holes cut into the big end reduced temperatures compared to the basic guard design. The modifications aim to improve heat transfer and lower muffler guard temperatures for enhanced performance and component life.
A compromise between the temperature difference and performance in a standing...محمود الأمير
Thermoacoustic refrigeration is an evolving cooling technology in which the acoustic power is used to pump heat. The operating conditions and geometric parameters are important for the thermoacoustic refrigerator performance, as they affect both its performance and the temperature difference across the stack. This paper investigates the effect of the stack geometric parameters and operating conditions on the performance of a standing wave thermoacoustic refrigerator and the temperature difference across the stack. DeltaEC software is used to make the thermoacoustic refrigerator model. From the obtained results,
normalised values for the operating conditions and geometric parameters are collected to compromise both the performance and the temperature difference across the stack.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
Medium carbon steel EN8 has a wide variety of applications in oil, gas and tool industries. It is most commonly
used where high tensile strength is required. In the present work, an attempt has been made to explore the effect
of machining parameters on Surface Roughness (Ra). Taguchi’s single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchi’s L27
Orthogonal array has been used. The input parameters selected are Pulse on time (PON), Pulse off time (POFF),
Wire tension (WT) and Wire feed (WF). From the Taguchi results, optimal combination of machining
parameters for Surface Roughness is found at Pulse-on time (PON) level 3(131μs), Pulse-off time (POFF) level 2
(58μs), Wire tension (WT) level 1(2 Kg-f) and Wire feed rate (WF) level 1(4m/min). ANOVA was used to find
the influence of machining parameters on Surface Roughness. From the results, it is found that wire feed rate
(WF) has high influence (F = 47.16) and Pulse-off time (TOFF) has very low influence (F = 1.57) in effecting the
Surface Roughness. Regression model for Surface Roughness has been prepared by using MINITAB-16
software. Experimental values and Regression values of Surface Roughness were compared and from the graph,
it is clear that both the values are very close to each other. Hence, Regression model prepared is accurate,
adequate and it can be used for the prediction of Surface Roughness.
This document discusses a study on the metal removal rate of aluminum composites during electrochemical machining. Experiments were conducted with voltage, feed rate, electrolyte concentration, and percentage of reinforcement as controllable parameters. A response surface methodology was used to develop a nonlinear regression model relating these input parameters to the metal removal rate output. Analysis of variance showed that all input parameters significantly affected the metal removal rate. Surface plots revealed that the metal removal rate increased with higher voltage, feed rate, and electrolyte concentration, but decreased with a higher percentage of reinforcement in the composite material.
This document summarizes a research paper that analyzes the heat transfer characteristics of an induction furnace using finite element analysis. It begins with an introduction to induction heating processes and describes the basic components of an induction furnace. The researchers aim to computationally validate the modified composite wall thickness of an induction furnace using heat transfer analysis. The document reviews several other studies on induction heating simulations and experimental validations. It then outlines the thermal modeling approach using the heat diffusion equation and describes the boundary conditions for the finite element analysis.
IRJET- Experimental Analysis of Circular Perforated Fin Arrays by Forced Conv...IRJET Journal
This document summarizes an experimental analysis of heat transfer from circular perforated fin arrays under forced convection using a wind tunnel. Trapezoidal microfin arrays with circular perforations were selected and designed using Taguchi Method. Experiments were conducted in a wind tunnel on three test specimens - a solid rectangular fin array and two trapezoidal perforated fin arrays with different perforation pitches. The perforated fin arrays showed higher overall efficiency and effectiveness compared to the solid fin array. Maximum overall efficiency was obtained for the array with 5mm perforation pitch at an air velocity of 2m/s and heat input of 150W. Optimum effectiveness was obtained for the array with 7mm pitch at 2m/s and 120W input
Performance Evaluation of Thermoelectric Materials: A Case Study of Orthorhom...inventionjournals
Designers often face the predicament of non-standardized and poor performing materials for thermoelectric module manufacturing. Other than analytical means, the only method to evaluate the performance of thermoelectric materials would be through experimental means. This work studies the experimental approach employed in performance investigation of thermoelectric materials using Orthorhombic SnSe crystals as a case study. The result obtained reveals the high thermoelectric conversion efficiency of orthorhombic crystals, and that they can operate as both low and high temperature thermoelectric material.
Optimization Potential of Induction Heating Systems by Stefan Schubotz and Ha...Fluxtrol Inc.
As published in Heat Processing (March 2015).
Depending on workpiece and process parameters, induction heating of components requires a certain amount of power. By simulation, experiments and experience, this needed energy can be well anticipated and enables the dimensioning of the converter. Basically, cost of the converter increases with rising provided power. Due to increasing energy expenses, efficiency of the system plays an important role. In this article, the influences of different process parameters on the efficiency of an example are investigated and valuable potential for improvement is demonstrated, so that the heating process is implemented with minimum converter power.
VIBRATION ANALYSIS FOR DAMAGE DETECTION IN COMPOSITE PLATE BY USING PIEZOELEC...IAEME Publication
This document summarizes a study on using piezoelectric sensors for vibration analysis and damage detection in composite plates. Piezoelectric wafer active sensors were attached to composite plate specimens containing embedded Teflon sheets to simulate damage. An experimental setup was used to generate actuation signals and record vibration responses from the sensors. Half-sine and rectangular impulse signals were tested. Frequency analysis of the monitored signals using wavelet transforms was performed to identify the presence and extent of damage. The study demonstrated the effectiveness of this active monitoring method for damage detection in composite structures.
Experimental and Numerical Study of a Steel Bridge Model through Vibration Te...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Comparative Study of Transient Conditions for Continuous Operation and Interm...IRJET Journal
This document summarizes a study that uses computational fluid dynamics (CFD) to compare the transient conditions of an Earth Air Tunnel Heat Exchanger (EATHE) system operated continuously versus intermittently in winter. Simulations were conducted for a 60m long pipe buried at 3.7m depth using three soil thermal conductivities. Results show intermittent operation provides a greater rise in air temperature compared to continuous operation, with more significant improvements seen for soil with lower thermal conductivity.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
This document presents a method for predicting coil copper temperatures in inductors to extend inductor lifetime. It discusses common failure modes of inductors and proposes calculating heat transfer coefficients and component temperatures. A case study applies the method to a seam annealing process on pipe. Simulations show copper temperatures are lower and more evenly distributed with a Fluxtrol flux controller compared to laminations, especially at higher power levels or intermittent heating. The method helps optimize inductor design for maximum lifetime.
This document summarizes an experimental study that analyzed the performance of small wind turbine blades with and without winglet additions. The study found that blades with winglets attached increased output power by 2.01% and reduced noise levels by 25% compared to blades without winglets. Computational fluid dynamics (CFD) modeling and noise analysis were used to simulate and compare blade performance. Testing of actual blade designs confirmed the CFD results, showing improved efficiency and reduced noise from blades with winglet additions at the tips.
This document summarizes a study assessing the suitability of shallow groundwater from coastal aquifers in Buguma City, Nigeria for irrigation purposes. Water samples from 100 wells across 20 locations were analyzed for various physicochemical parameters including heavy metals, salinity, pH, sodium adsorption ratio, and more. The results showed elevated levels of iron and sodium adsorption ratio that exceed standards for irrigation water in many locations. This indicates the water is generally unsuitable for irrigation due to risks of clogging irrigation systems, displacing calcium in soil, and causing soil and plant health issues like stunted growth. Only 3 of the 20 locations were found to have water suitable for irrigation based on the water quality index and parameter assessment.
The document investigates the use of fly ash to stabilize low shear strength soil by conducting laboratory tests to evaluate the compaction and unconfined compressive strength of soil mixtures with varying percentages of fly ash. The results show that mixing 10% fly ash by weight increased the maximum shear strength of the soil by 4% while not significantly changing the internal friction. In general, adding fly ash improved the engineering properties and stability of the soil.
- The document discusses food waste in the United States, noting that 30-40% of food is thrown out and that overbuying by consumers and overordering by stores contributes to this problem. It also mentions that saving 15% of the food currently wasted could feed 25 million people.
- The rest of the document appears to be a collection of images posted by Kelsey Kresge related to creating graphics and a logo for a hypothetical organization called the Conservation Kitchen focused on reducing food waste. The images show logo design sketches, a final logo, and designs for a t-shirt and book cover featuring the logo.
A Study on Stochastic Thermal Characterization of Electronic PackagesIJERA Editor
Insofar as the electronics can be found now in several applications of multiple domains, we have tried to
highlight in this study that, those systems must be based on unquestionable reliability and meet the needs of the
external environment. Starting from the unit "°c / w" concerning the thermal resistance from the gap between
junction temperature and a reference temperature, we have tried to compare the thermal performance of
electronic packages taking into consideration the thermal management. Our approach is based on the Monte
Carlo simulation and the stochastic characterization of the QFN. From the norm of normalization, we have
obtained standardized data sheets allowing accurate comparisons of the thermal performance of electronic
packages as produced by different manufacturers. Our numerical model through simulation, prototyping
concerning the design involves the JEDEC recommendations, which we consider a very interesting alternative.
Through the deterministic analysis, we conducted an analysis from the Matlab program parameters, which
control the Ansys software, the results were processed by statistical techniques to evaluate the times of the
thermal resistance of the QFN. That is why we must consider the electronic package (encapsulating the
integrated circuit), through the printed circuit board (PCB) to ensure the junction temperature maintenance and
avoid the dissipation of the heat. Also our process was based on the union of the finite element method to the
Monte Carlo simulation and stochastic characterization of the QFN.
Keywords: Electronic package; Finite element method; printed
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
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.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
IRJET- Experimental Analysis for Thermal Performance of Muffler Guard Hero Xt...IRJET Journal
This document summarizes an experimental analysis of the thermal performance of a muffler guard for a Hero XTREME 200R motorcycle. The study designs and models a basic and modified muffler guard using CAD software. Temperature measurements are taken at points on the basic and modified guards under idling and running engine conditions using an infrared thermometer. Graphs of the temperature data show the modified guard with vertical and horizontal holes cut into the big end reduced temperatures compared to the basic guard design. The modifications aim to improve heat transfer and lower muffler guard temperatures for enhanced performance and component life.
A compromise between the temperature difference and performance in a standing...محمود الأمير
Thermoacoustic refrigeration is an evolving cooling technology in which the acoustic power is used to pump heat. The operating conditions and geometric parameters are important for the thermoacoustic refrigerator performance, as they affect both its performance and the temperature difference across the stack. This paper investigates the effect of the stack geometric parameters and operating conditions on the performance of a standing wave thermoacoustic refrigerator and the temperature difference across the stack. DeltaEC software is used to make the thermoacoustic refrigerator model. From the obtained results,
normalised values for the operating conditions and geometric parameters are collected to compromise both the performance and the temperature difference across the stack.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
Medium carbon steel EN8 has a wide variety of applications in oil, gas and tool industries. It is most commonly
used where high tensile strength is required. In the present work, an attempt has been made to explore the effect
of machining parameters on Surface Roughness (Ra). Taguchi’s single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchi’s L27
Orthogonal array has been used. The input parameters selected are Pulse on time (PON), Pulse off time (POFF),
Wire tension (WT) and Wire feed (WF). From the Taguchi results, optimal combination of machining
parameters for Surface Roughness is found at Pulse-on time (PON) level 3(131μs), Pulse-off time (POFF) level 2
(58μs), Wire tension (WT) level 1(2 Kg-f) and Wire feed rate (WF) level 1(4m/min). ANOVA was used to find
the influence of machining parameters on Surface Roughness. From the results, it is found that wire feed rate
(WF) has high influence (F = 47.16) and Pulse-off time (TOFF) has very low influence (F = 1.57) in effecting the
Surface Roughness. Regression model for Surface Roughness has been prepared by using MINITAB-16
software. Experimental values and Regression values of Surface Roughness were compared and from the graph,
it is clear that both the values are very close to each other. Hence, Regression model prepared is accurate,
adequate and it can be used for the prediction of Surface Roughness.
This document discusses a study on the metal removal rate of aluminum composites during electrochemical machining. Experiments were conducted with voltage, feed rate, electrolyte concentration, and percentage of reinforcement as controllable parameters. A response surface methodology was used to develop a nonlinear regression model relating these input parameters to the metal removal rate output. Analysis of variance showed that all input parameters significantly affected the metal removal rate. Surface plots revealed that the metal removal rate increased with higher voltage, feed rate, and electrolyte concentration, but decreased with a higher percentage of reinforcement in the composite material.
This document summarizes a research paper that analyzes the heat transfer characteristics of an induction furnace using finite element analysis. It begins with an introduction to induction heating processes and describes the basic components of an induction furnace. The researchers aim to computationally validate the modified composite wall thickness of an induction furnace using heat transfer analysis. The document reviews several other studies on induction heating simulations and experimental validations. It then outlines the thermal modeling approach using the heat diffusion equation and describes the boundary conditions for the finite element analysis.
IRJET- Experimental Analysis of Circular Perforated Fin Arrays by Forced Conv...IRJET Journal
This document summarizes an experimental analysis of heat transfer from circular perforated fin arrays under forced convection using a wind tunnel. Trapezoidal microfin arrays with circular perforations were selected and designed using Taguchi Method. Experiments were conducted in a wind tunnel on three test specimens - a solid rectangular fin array and two trapezoidal perforated fin arrays with different perforation pitches. The perforated fin arrays showed higher overall efficiency and effectiveness compared to the solid fin array. Maximum overall efficiency was obtained for the array with 5mm perforation pitch at an air velocity of 2m/s and heat input of 150W. Optimum effectiveness was obtained for the array with 7mm pitch at 2m/s and 120W input
Performance Evaluation of Thermoelectric Materials: A Case Study of Orthorhom...inventionjournals
Designers often face the predicament of non-standardized and poor performing materials for thermoelectric module manufacturing. Other than analytical means, the only method to evaluate the performance of thermoelectric materials would be through experimental means. This work studies the experimental approach employed in performance investigation of thermoelectric materials using Orthorhombic SnSe crystals as a case study. The result obtained reveals the high thermoelectric conversion efficiency of orthorhombic crystals, and that they can operate as both low and high temperature thermoelectric material.
Optimization Potential of Induction Heating Systems by Stefan Schubotz and Ha...Fluxtrol Inc.
As published in Heat Processing (March 2015).
Depending on workpiece and process parameters, induction heating of components requires a certain amount of power. By simulation, experiments and experience, this needed energy can be well anticipated and enables the dimensioning of the converter. Basically, cost of the converter increases with rising provided power. Due to increasing energy expenses, efficiency of the system plays an important role. In this article, the influences of different process parameters on the efficiency of an example are investigated and valuable potential for improvement is demonstrated, so that the heating process is implemented with minimum converter power.
VIBRATION ANALYSIS FOR DAMAGE DETECTION IN COMPOSITE PLATE BY USING PIEZOELEC...IAEME Publication
This document summarizes a study on using piezoelectric sensors for vibration analysis and damage detection in composite plates. Piezoelectric wafer active sensors were attached to composite plate specimens containing embedded Teflon sheets to simulate damage. An experimental setup was used to generate actuation signals and record vibration responses from the sensors. Half-sine and rectangular impulse signals were tested. Frequency analysis of the monitored signals using wavelet transforms was performed to identify the presence and extent of damage. The study demonstrated the effectiveness of this active monitoring method for damage detection in composite structures.
Experimental and Numerical Study of a Steel Bridge Model through Vibration Te...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Comparative Study of Transient Conditions for Continuous Operation and Interm...IRJET Journal
This document summarizes a study that uses computational fluid dynamics (CFD) to compare the transient conditions of an Earth Air Tunnel Heat Exchanger (EATHE) system operated continuously versus intermittently in winter. Simulations were conducted for a 60m long pipe buried at 3.7m depth using three soil thermal conductivities. Results show intermittent operation provides a greater rise in air temperature compared to continuous operation, with more significant improvements seen for soil with lower thermal conductivity.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
This document presents a method for predicting coil copper temperatures in inductors to extend inductor lifetime. It discusses common failure modes of inductors and proposes calculating heat transfer coefficients and component temperatures. A case study applies the method to a seam annealing process on pipe. Simulations show copper temperatures are lower and more evenly distributed with a Fluxtrol flux controller compared to laminations, especially at higher power levels or intermittent heating. The method helps optimize inductor design for maximum lifetime.
This document summarizes an experimental study that analyzed the performance of small wind turbine blades with and without winglet additions. The study found that blades with winglets attached increased output power by 2.01% and reduced noise levels by 25% compared to blades without winglets. Computational fluid dynamics (CFD) modeling and noise analysis were used to simulate and compare blade performance. Testing of actual blade designs confirmed the CFD results, showing improved efficiency and reduced noise from blades with winglet additions at the tips.
This document summarizes a study assessing the suitability of shallow groundwater from coastal aquifers in Buguma City, Nigeria for irrigation purposes. Water samples from 100 wells across 20 locations were analyzed for various physicochemical parameters including heavy metals, salinity, pH, sodium adsorption ratio, and more. The results showed elevated levels of iron and sodium adsorption ratio that exceed standards for irrigation water in many locations. This indicates the water is generally unsuitable for irrigation due to risks of clogging irrigation systems, displacing calcium in soil, and causing soil and plant health issues like stunted growth. Only 3 of the 20 locations were found to have water suitable for irrigation based on the water quality index and parameter assessment.
The document investigates the use of fly ash to stabilize low shear strength soil by conducting laboratory tests to evaluate the compaction and unconfined compressive strength of soil mixtures with varying percentages of fly ash. The results show that mixing 10% fly ash by weight increased the maximum shear strength of the soil by 4% while not significantly changing the internal friction. In general, adding fly ash improved the engineering properties and stability of the soil.
- The document discusses food waste in the United States, noting that 30-40% of food is thrown out and that overbuying by consumers and overordering by stores contributes to this problem. It also mentions that saving 15% of the food currently wasted could feed 25 million people.
- The rest of the document appears to be a collection of images posted by Kelsey Kresge related to creating graphics and a logo for a hypothetical organization called the Conservation Kitchen focused on reducing food waste. The images show logo design sketches, a final logo, and designs for a t-shirt and book cover featuring the logo.
La ecología estudia las interrelaciones entre los seres vivos y su entorno. Examina cómo las interacciones entre organismos y factores ambientales como el clima afectan la distribución y abundancia de las especies. Los ecosistemas están compuestos de organismos, comunidades y componentes no vivos que interactúan dinámicamente a través de procesos como la producción primaria y el ciclo de nutrientes. La ecología analiza estos procesos y las interacciones entre organismos para comprender cómo se distribuyen y abundan en el medio ambiente.
This document summarizes research on detecting replica nodes in wireless sensor networks. It first discusses how adversaries can create replica nodes by compromising sensor nodes and stealing their keying materials. It then reviews various approaches for replica node detection, including using tamper-resistant hardware, randomized efficient distributed protocols, and leveraging knowledge of sensor deployment locations. The document proposes a new scheme using sequential probability ratio testing to detect mobile replica nodes based on analyzing the speeds between consecutive location claims from sensor nodes. This approach aims to quickly detect replica nodes compared to existing techniques.
Tecnodiario y sus aportes a la educación modernaUNED
El documento describe los aportes de Tecnodiario a la educación moderna, incluyendo la utilización de herramientas tecnológicas en el currículo escolar para fomentar el aprendizaje significativo y la creatividad en los estudiantes, y el desarrollo de competencias mediante el uso de la tecnología para alcanzar objetivos educativos. También presenta conclusiones sobre el uso del portafolio de aprendizajes y experiencias del curso, destacando el uso de aplicaciones web para apoyar los contenidos académic
This document assesses the liquefaction potential for the approach road of the Padma Multipurpose Bridge project in Bangladesh. Standard penetration tests were conducted at borehole locations along the road to evaluate factors of safety against liquefaction. Liquefaction potential index (LPI) values were calculated for different earthquake magnitudes and peak ground accelerations using the borehole data. Contour maps of LPI values created in MATLAB show high liquefaction potential at many locations due to thick, loose alluvial deposits and a high water table. The LPI maps can help engineers evaluate liquefaction hazards and design appropriate mitigation measures for the project.
This document discusses optimizing wire electrical discharge machining (WEDM) process parameters using the Taguchi method and grey relational analysis. It describes WEDM, the process parameters tested, and the Taguchi experimental design used. The document outlines the steps of the grey-based Taguchi method applied, including calculating signal-to-noise ratios for responses, determining the optimal levels of factors, and comparing results from tables and graphs. Charts show the main effects of varying pulse on time, pulse off time, and peak current on material removal rate, electrode consumption, and surface roughness.
Este documento resume las características principales del fútbol americano. Explica que es un deporte de conjunto que nació en Estados Unidos y requiere gran disciplina y entrenamiento físico. Describe la liga profesional NFL, sus equipos y estadios. Incluye detalles sobre el campo de juego, reglas básicas, posiciones clave y la historia del deporte.
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
Los Juegos Olímpicos de la Antigüedad se originaron en Grecia en el siglo IX a.C. como competiciones deportivas y religiosas en honor a los dioses del Olimpo. Los primeros Juegos Olímpicos modernos se celebraron en Atenas en 1896 para recuperar el espíritu olímpico. Argentina ha participado en los Juegos Olímpicos desde 1900, ganando medallas en boxeo, natación y esgrima.
NJ Future Redevelopment Forum 2017 Reigniting Stalled ProjectsNew Jersey Future
The document summarizes the redevelopment of a blighted 30-year vacant site in Plainfield, NJ into a mixed-use development with commercial and residential components. A 44,000 square foot warehouse was constructed for ABC Supply and 90 affordable housing units will be built utilizing low-income housing tax credits. The project overcame challenges like environmental issues and negotiated approvals from the municipality within one year by utilizing tax incentives and financing tools. Coordination between the developer, municipal bodies, funding institutions, and state agencies was required to successfully execute the redevelopment within an aggressive timeline.
Optimization of MRR and SR by employing Taguchis and ANOVA method in EDMIRJET Journal
The document describes research into optimizing material removal rate (MRR) and surface roughness (SR) in electric discharge machining (EDM). Experiments were conducted with four machining parameters (discharge current, source voltage, pulse-on time, and pulse-off time) at different levels using a Taguchi design of experiments approach. Analysis of variance (ANOVA) found that discharge current contributed most to MRR at 33.33%, while pulse-on time contributed most to SR at 30.62%. The study aims to apply Taguchi and ANOVA methods to optimize MRR and SR in EDM.
IRJET- A Review Study of Thermal Electrical Model using ANSYS SoftwareIRJET Journal
This document summarizes a research study that used ANSYS software to design a thermal-electrical model for sparks generated during electrical discharge machining (EDM) and determine temperature distribution. The study aimed to model the EDM process, predict maximum temperature, and estimate material removal rate from the workpiece. Experiments were conducted using different pulse on-times and currents on an EN-19 workpiece. Results showed that material removal rate increased with higher current and pulse on-time, and was in agreement with finite element analysis results. The temperature distribution curve was also able to estimate the maximum material removal rate.
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.
Electrical discharge machining is basically a non-conventional material removal process which is widely used to produce dies, punches and moulds, finishing parts for aerospace and automotive industry, and surgical components. This process can be successfully employed to machine electrically conductive parts irrespective of their hardness, shape and toughness.
IRJET- Parametric Optimization of Powder Mixed Electronic Discharge Machine.IRJET Journal
The document summarizes a study that optimized the process parameters of powder mixed electrical discharge machining (PMEDM) to maximize material removal rate and minimize tool wear rate and surface roughness. Key parameters investigated included peak current, pulse on time, and aluminum powder concentration. Experiments were designed using Taguchi methodology and analyzed in MINITAB 18 software. The results showed that peak current had the greatest influence on material removal rate, while aluminum powder concentration had the greatest influence on tool wear rate and surface roughness. Recommended optimal parameter settings were determined through confirmation experiments.
This document provides a review of optimization techniques for the wire electrical discharge machining (WEDM) process. It begins with an introduction to WEDM, describing the working principle and important process parameters like pulse width, time between pulses, servo reference voltage, and wire tension. The document then reviews literature on optimization methods that have been used to maximize material removal rate while minimizing electrode wear rate. Specifically, it discusses two studies that used Taguchi's design of experiments approach and desirability functions to optimize cutting conditions for different materials like minimizing wear rate and maximizing material removal rate in WEDM.
A Review Study On Optimisation Of Process Of Wedm And Its DevelopmentIOSR Journals
This document provides a review of optimization techniques used to improve the process of wire electrical discharge machining (WEDM). It begins with an abstract summarizing the paper's focus on developing and optimizing WEDM processes. The introduction discusses key aspects of WEDM like operating parameters, material removal rate, surface finish, and electrode wear rate. It also outlines the working principle and a diagram of the WEDM process. The literature survey section summarizes several past studies that optimized WEDM parameters like pulse on/off time and current using techniques like the Taguchi method and response surface methodology. The conclusion is that more research could optimize parameters and responses for different materials and tool materials.
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.
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
IRJET-Experimental Analysis Optimization of Process Parameters of Wire EDM on...IRJET Journal
This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
Review Study and Importance of Micro Electric Discharge Machiningsushil Choudhary
Micro EDM process is one of the micro- machining processes. It can be used to machine micro features and
makes a micro parts. There is a huge demand in the production of microstructures by a non-traditional method
which known as Micro-EDM. Micro-EDM process is based on the thermoelectric energy between the workpiece
and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of
50 μm -100 μm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with
various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges
occur in a small gap between the work piece and the electrode and at the same time removes the unwanted
material from the parent metal through the process of melting and vaporization. This paper describes the
importance, parameters, principle, difference between Macro and micro EDM, applications and advantages of μ-
EDM and discuss about the literature reviews based on performance measure in micro- EDMP process.
Fabrication of Micro Electrodes for EDM and Optimization of the Process Param...IRJET Journal
This document describes research on fabricating micro electrodes for micro electrical discharge machining (Micro-EDM) and optimizing process parameters to maximize the machining rate (MR). Micro electrodes with high aspect ratios were fabricated in a copper block using tubular copper electrodes through electrical discharge drilling (EDD). An L9 orthogonal array was used to experiment with discharge current, pulse-on time, and pulse-off time as process parameters. Taguchi's approach was used to analyze the results and optimize the parameters for maximum MR. The optimal parameters predicted an MR of 4.86 mm/min, close to the experimental value of 4.95 mm/min. Scanning electron microscope (SEM) images showed the fabricated micro electrodes.
Experimental Investigation to Determine Influence of Process Parameters on Su...IRJET Journal
This document summarizes an experimental investigation into determining the influence of process parameters on surface quality in wire cut electrical discharge machining (WEDM). The study examines the relationship between input process parameters like pulse-on time, pulse-off time, peak current, wire material, and workpiece material, and output variables like surface roughness and electrode wear. Experiments were conducted using an aluminum workpiece material and brass wire electrode. Based on the chosen input parameters and performance measures, a L9 orthogonal array was used to optimize the process parameters for machining aluminum alloys by WEDM.
Comparative study on variation of process characteristics on al and die steel...IAEME Publication
This document presents the results of an experimental study on the influence of electrical discharge machining (EDM) parameters on process characteristics when machining aluminum (Al) and die steel components. Specifically, it examines the effect of changing current on material removal rate, tool wear ratio, and surface roughness for the two materials. The results showed that increasing current from 10A to 20A led to higher material removal rates and tool wear ratios for both Al and die steel. It also resulted in increased surface roughness parameters (average roughness, average maximum height, maximum roughness depth) for the machined surfaces of both materials. The findings provide information on selecting optimal current parameters to achieve desired EDM efficiency and surface finish when machining Al and die steel
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.
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.
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
Optimization of Process Parameters for Deep Hole Drilling using Drill EDM for...IRJET Journal
The document discusses optimizing process parameters for deep hole drilling using electric discharge machining (EDM) on tungsten carbide. Experiments were conducted using a copper electrode to drill holes in tungsten carbide. The parameters of discharge current, pulse on time, and pulse off time were optimized using Taguchi methods to maximize machining rate and minimize electrode wear ratio. Grey relation analysis was used to determine a single optimized set of parameters that considers both responses. The optimal parameters found were a discharge current of 6A, pulse on time of 6μs, and pulse off time of 5μs.
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.
The document discusses experimentation on controlling tool wear during electric discharge machining (EDM) using statistical analysis and optimization techniques. Key points:
1) The experiment uses EN-31 material with copper electrodes and analyzes process parameters like discharge current, pulse on/off time on tool wear using Taguchi's design of experiments.
2) Analysis of variance (ANOVA) indicates discharge current, pulse on time, and pulse off time significantly affect tool wear.
3) The goal is to determine optimal parameter levels to minimize tool wear and validate the solution through experimentation on an EDM machine and statistical software.
This document provides a technical review of secure banking using RSA and AES encryption methodologies. It discusses how RSA and AES are commonly used encryption standards for secure data transmission between ATMs and bank servers. The document first provides background on ATM security measures and risks of attacks. It then reviews related work analyzing encryption techniques. The document proposes using a one-time password in addition to a PIN for ATM authentication. It concludes that implementing encryption standards like RSA and AES can make transactions more secure and build trust in online banking.
This document analyzes the performance of various modulation schemes for achieving energy efficient communication over fading channels in wireless sensor networks. It finds that for long transmission distances, low-order modulations like BPSK are optimal due to their lower SNR requirements. However, as transmission distance decreases, higher-order modulations like 16-QAM and 64-QAM become more optimal since they can transmit more bits per symbol, outweighing their higher SNR needs. Simulations show lifetime extensions up to 550% are possible in short-range networks by using higher-order modulations instead of just BPSK. The optimal modulation depends on transmission distance and balancing the energy used by electronic components versus power amplifiers.
This document provides a review of mobility management techniques in vehicular ad hoc networks (VANETs). It discusses three modes of communication in VANETs: vehicle-to-infrastructure (V2I), vehicle-to-vehicle (V2V), and hybrid vehicle (HV) communication. For each communication mode, different mobility management schemes are required due to their unique characteristics. The document also discusses mobility management challenges in VANETs and outlines some open research issues in improving mobility management for seamless communication in these dynamic networks.
This document provides a review of different techniques for segmenting brain MRI images to detect tumors. It compares the K-means and Fuzzy C-means clustering algorithms. K-means is an exclusive clustering algorithm that groups data points into distinct clusters, while Fuzzy C-means is an overlapping clustering algorithm that allows data points to belong to multiple clusters. The document finds that Fuzzy C-means requires more time for brain tumor detection compared to other methods like hierarchical clustering or K-means. It also reviews related work applying these clustering algorithms to segment brain MRI images.
1) The document simulates and compares the performance of AODV and DSDV routing protocols in a mobile ad hoc network under three conditions: when users are fixed, when users move towards the base station, and when users move away from the base station.
2) The results show that both protocols have higher packet delivery and lower packet loss when users are either fixed or moving towards the base station, since signal strength is better in those scenarios. Performance degrades when users move away from the base station due to weaker signals.
3) AODV generally has better performance than DSDV, with higher throughput and packet delivery rates observed across the different user mobility conditions.
This document describes the design and implementation of 4-bit QPSK and 256-bit QAM modulation techniques using MATLAB. It compares the two techniques based on SNR, BER, and efficiency. The key steps of implementing each technique in MATLAB are outlined, including generating random bits, modulation, adding noise, and measuring BER. Simulation results show scatter plots and eye diagrams of the modulated signals. A table compares the results, showing that 256-bit QAM provides better performance than 4-bit QPSK. The document concludes that QAM modulation is more effective for digital transmission systems.
The document proposes a hybrid technique using Anisotropic Scale Invariant Feature Transform (A-SIFT) and Robust Ensemble Support Vector Machine (RESVM) to accurately identify faces in images. A-SIFT improves upon traditional SIFT by applying anisotropic scaling to extract richer directional keypoints. Keypoints are processed with RESVM and hypothesis testing to increase accuracy above 95% by repeatedly reprocessing images until the threshold is met. The technique was tested on similar and different facial images and achieved better results than SIFT in retrieval time and reduced keypoints.
This document studies the effects of dielectric superstrate thickness on microstrip patch antenna parameters. Three types of probes-fed patch antennas (rectangular, circular, and square) were designed to operate at 2.4 GHz using Arlondiclad 880 substrate. The antennas were tested with and without an Arlondiclad 880 superstrate of varying thicknesses. It was found that adding a superstrate slightly degraded performance by lowering the resonant frequency and increasing return loss and VSWR, while decreasing bandwidth and gain. Specifically, increasing the superstrate thickness or dielectric constant resulted in greater changes to the antenna parameters.
This document describes a wireless environment monitoring system that utilizes soil energy as a sustainable power source for wireless sensors. The system uses a microbial fuel cell to generate electricity from the microbial activity in soil. Two microbial fuel cells were created using different soil types and various additives to produce different current and voltage outputs. An electronic circuit was designed on a printed circuit board with components like a microcontroller and ZigBee transceiver. Sensors for temperature and humidity were connected to the circuit to monitor the environment wirelessly. The system provides a low-cost way to power remote sensors without needing battery replacement and avoids the high costs of wiring a power source.
1) The document proposes a model for a frequency tunable inverted-F antenna that uses ferrite material.
2) The resonant frequency of the antenna can be significantly shifted from 2.41GHz to 3.15GHz, a 31% shift, by increasing the static magnetic field placed on the ferrite material.
3) Altering the permeability of the ferrite allows tuning of the antenna's resonant frequency without changing the physical dimensions, providing flexibility to operate over a wide frequency range.
This document summarizes a research paper that presents a speech enhancement method using stationary wavelet transform. The method first classifies speech into voiced, unvoiced, and silence regions based on short-time energy. It then applies different thresholding techniques to the wavelet coefficients of each region - modified hard thresholding for voiced speech, semi-soft thresholding for unvoiced speech, and setting coefficients to zero for silence. Experimental results using speech from the TIMIT database corrupted with white Gaussian noise at various SNR levels show improved performance over other popular denoising methods.
This document reviews the design of an energy-optimized wireless sensor node that encrypts data for transmission. It discusses how sensing schemes that group nodes into clusters and transmit aggregated data can reduce energy consumption compared to individual node transmissions. The proposed node design calculates the minimum transmission power needed based on received signal strength and uses a periodic sleep/wake cycle to optimize energy when not sensing or transmitting. It aims to encrypt data at both the node and network level to further optimize energy usage for wireless communication.
This document discusses group consumption modes. It analyzes factors that impact group consumption, including external environmental factors like technological developments enabling new forms of online and offline interactions, as well as internal motivational factors at both the group and individual level. The document then proposes that group consumption modes can be divided into four types based on two dimensions: vertical (group relationship intensity) and horizontal (consumption action period). These four types are instrument-oriented, information-oriented, enjoyment-oriented, and relationship-oriented consumption modes. Finally, the document notes that consumption modes are dynamic and can evolve over time.
The document summarizes a study of different microstrip patch antenna configurations with slotted ground planes. Three antenna designs were proposed and their performance evaluated through simulation: a conventional square patch, an elliptical patch, and a star-shaped patch. All antennas were mounted on an FR4 substrate. The effects of adding different slot patterns to the ground plane on resonance frequency, bandwidth, gain and efficiency were analyzed parametrically. Key findings were that reshaping the patch and adding slots increased bandwidth and shifted resonance frequency. The elliptical and star patches in particular performed better than the conventional design. Three antenna configurations were selected for fabrication and measurement based on the simulations: a conventional patch with a slot under the patch, an elliptical patch with slots
1) The document describes a study conducted to improve call drop rates in a GSM network through RF optimization.
2) Drive testing was performed before and after optimization using TEMS software to record network parameters like RxLevel, RxQuality, and events.
3) Analysis found call drops were occurring due to issues like handover failures between sectors, interference from adjacent channels, and overshooting due to antenna tilt.
4) Corrective actions taken included defining neighbors between sectors, adjusting frequencies to reduce interference, and lowering the mechanical tilt of an antenna.
5) Post-optimization drive testing showed improvements in RxLevel, RxQuality, and a reduction in dropped calls.
This document describes the design of an intelligent autonomous wheeled robot that uses RF transmission for communication. The robot has two modes - automatic mode where it can make its own decisions, and user control mode where a user can control it remotely. It is designed using a microcontroller and can perform tasks like object recognition using computer vision and color detection in MATLAB, as well as wall painting using pneumatic systems. The robot's movement is controlled by DC motors and it uses sensors like ultrasonic sensors and gas sensors to navigate autonomously. RF transmission allows communication between the robot and a remote control unit. The overall aim is to develop a low-cost robotic system for industrial applications like material handling.
This document reviews cryptography techniques to secure the Ad-hoc On-Demand Distance Vector (AODV) routing protocol in mobile ad-hoc networks. It discusses various types of attacks on AODV like impersonation, denial of service, eavesdropping, black hole attacks, wormhole attacks, and Sybil attacks. It then proposes using the RC6 cryptography algorithm to secure AODV by encrypting data packets and detecting and removing malicious nodes launching black hole attacks. Simulation results show that after applying RC6, the packet delivery ratio and throughput of AODV increase while delay decreases, improving the security and performance of the network under attack.
The document describes a proposed modification to the conventional Booth multiplier that aims to increase its speed by applying concepts from Vedic mathematics. Specifically, it utilizes the Urdhva Tiryakbhyam formula to generate all partial products concurrently rather than sequentially. The proposed 8x8 bit multiplier was coded in VHDL, simulated, and found to have a path delay 44.35% lower than a conventional Booth multiplier, demonstrating its potential for higher speed.
This document discusses image deblurring techniques. It begins by introducing image restoration and focusing on image deblurring. It then discusses challenges with image deblurring being an ill-posed problem. It reviews existing approaches to screen image deconvolution including estimating point spread functions and iteratively estimating blur kernels and sharp images. The document also discusses handling spatially variant blur and summarizes the relationship between the proposed method and previous work for different blur types. It proposes using color filters in the aperture to exploit parallax cues for segmentation and blur estimation. Finally, it proposes moving the image sensor circularly during exposure to prevent high frequency attenuation from motion blur.
This document describes modeling an adaptive controller for an aircraft roll control system using PID, fuzzy-PID, and genetic algorithm. It begins by introducing the aircraft roll control system and motivation for developing an adaptive controller to minimize errors from noisy analog sensor signals. It then provides the mathematical model of aircraft roll dynamics and describes modeling the real-time flight control system in MATLAB/Simulink. The document evaluates PID, fuzzy-PID, and PID-GA (genetic algorithm) controllers for aircraft roll control and finds that the PID-GA controller delivers the best performance.
Threats to mobile devices are more prevalent and increasing in scope and complexity. Users of mobile devices desire to take full advantage of the features
available on those devices, but many of the features provide convenience and capability but sacrifice security. This best practices guide outlines steps the users can take to better protect personal devices and information.
Unlock the Future of Search with MongoDB Atlas_ Vector Search Unleashed.pdfMalak Abu Hammad
Discover how MongoDB Atlas and vector search technology can revolutionize your application's search capabilities. This comprehensive presentation covers:
* What is Vector Search?
* Importance and benefits of vector search
* Practical use cases across various industries
* Step-by-step implementation guide
* Live demos with code snippets
* Enhancing LLM capabilities with vector search
* Best practices and optimization strategies
Perfect for developers, AI enthusiasts, and tech leaders. Learn how to leverage MongoDB Atlas to deliver highly relevant, context-aware search results, transforming your data retrieval process. Stay ahead in tech innovation and maximize the potential of your applications.
#MongoDB #VectorSearch #AI #SemanticSearch #TechInnovation #DataScience #LLM #MachineLearning #SearchTechnology
Let's Integrate MuleSoft RPA, COMPOSER, APM with AWS IDP along with Slackshyamraj55
Discover the seamless integration of RPA (Robotic Process Automation), COMPOSER, and APM with AWS IDP enhanced with Slack notifications. Explore how these technologies converge to streamline workflows, optimize performance, and ensure secure access, all while leveraging the power of AWS IDP and real-time communication via Slack notifications.
AI 101: An Introduction to the Basics and Impact of Artificial IntelligenceIndexBug
Imagine a world where machines not only perform tasks but also learn, adapt, and make decisions. This is the promise of Artificial Intelligence (AI), a technology that's not just enhancing our lives but revolutionizing entire industries.
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Prompting language models is hard, while programming language models is easy. In this talk, I will discuss the state-of-the-art framework DSPy for programming foundation models with its powerful optimizers and runtime constraint system.
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J1303057185
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13, Issue 3 Ver. V (May- Jun. 2016), PP 71-85
www.iosrjournals.org
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 71 | Page
Predicting Optimized EDM Machining Parameter through
Thermo Mechanical Analysis
AbhinandanA. Gosavi#
, Prof.A. B. Gaikwad#
#
Department of Mechanical Engineering,Dr. D. Y. Patil School of engineering, Charholi(Bk), Pune-
412105,SavitribaiPhule Pune University.
Abstract: Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes.
EDM process is based on thermo electric energy between an electrode and the workpiece. The important
process parameters in this technique are current, discharge pulse on time, discharge pulse off and gap
voltage. The values of these parameters significantly affect the machining outputs material removal rate.
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
also due to difficulty of EDM, for improving cutting performance.it is very complicated to determine optimal
cutting parameters, which is an important action in machining and modelling is necessary to make a precise
relation between input and output parameters. In the present research, an axisymmetric thermo-physical finite
element model for the simulation of single sparks machining is presented to analyse the process parameters
and their effect on important responses such as material removal rate on work piece material OHNS Die steel
(EN31) in electrical discharge machining (EDM) process and the model has been solved by using ANSYS 16.0
software. The model is validated conducting experiments on an EDM machine. To study the performance of
machining before actual cutting operation this numerical method provides an inexpensive and time saving
alternative solution. A transient thermal analysis assuming a Gaussian distribution heat source with
temperature-dependent material properties has been used to investigate the temperature distribution on the
surface. Material removal rate (MRR) was calculated for multi-discharge machining by taking into
considerations the number of pulses. Comparison of the theoretical result ,experimental result and ANN
process model result by considering the same process parameters has been done, and the result is highly
agreed between the experimental and theoretical value.
Keywords: Finite element approach, Numerical Analysis; Electrical Discharge Machining; Modeling,
Optimization Process
I. Introduction
Electrical discharge machining is a thermal process that involves melting and vaporization of the
workpiece electrode. It is widely used in the aerospace, mould making and die casting industries for
manufacturing plastics moulds, forging dies and die casting dies made from hardened tool steels, together with
engine components, such as compressor blades made from titanium alloys and nickel-based super alloys. The
EDM process uses electrical discharges to remove material from the workpiece, with each spark producing a
temperature of between 10,000-20,000°C. Consequently, the workpiece is subjected to a heat affected zone
(HAZ) the top layer of which comprises recast material. The thickness, composition and condition of this layer
depend on the discharge energy and the make-up of the workpiece, tool electrode and dielectric fluid, and both
hard and soft surface layers can be produced despite perceived wisdom that the recast layer is always hard. Also
it can be defined as process of material removal by controlled erosion through a series of electric sparks.
Electrical energy is used to generate electrical spark and material removal mainly occurs due to thermal energy
of the spark. EDM can be used to machine difficult geometries in small batches or even on job-shop basis. Work
material to be machined by EDM has to be electrically conductive:
The complex nature of the process involving behavior of the EDM spark makes it even tougher to
analyze the process experimentally and quantifies the process responses. The frequencies of an original shape
and modified shape should be within range. The process has however, some limitations such as high specific
energy consumption, longer lead times and lower productivity which limit its applications. Researchers
worldwide are thus, focusing on process modeling and optimization of EDM to improve the productivity and
finishing capability of the process
Due to the complex and non-linear relationship between the input process parameters and output
performance parameters, it is quite difficult to develop an accurate process model and use it to select the
optimum process parameters for EDM process. The focus of the present work is thus, on developing an
intelligent approach for process modeling and optimization of EDM process and to predict process responses
such material removal rate (MRR) from the process parameters. Physics based process modeling using FEM has
2. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 72 | Page
been used to improve prediction accuracy of the model with less dependency on the experimental data. This
approach will help a process engineer to improve the process productivity, finishing capability and economical
operation of die-sinking EDM process.
II. Literature Review
According to Vinothkumar.S, “Electro Thermal Modelling of Micro EDM”, he analyzed in his
investigation of Finite element modelling of RC-circuit Micro-EDM process has been carried out to predict the
MRR using Finite element analysis software ANSYS (v.12). This model considers Capacitance, Resistance and
Voltage to predict temperature distribution on the workpiece. The results have been verified with the
experimental investigation performed with the pure copper as the tool electrode and AISI 304 stainless steel as
the workpiece. [1]
According to Chinmaya P. Mohantya*, JambeswarSahub, S.S.Mahapatraa “Thermal-structural
Analysis of Electrical Discharge Machining Process” In the his present work, a thermal-structural model is
presented to analyze the process parameters and their effect on three important responses such as material
removal rate, tool wear rate and residual stresses on work piece in electrical discharge machining (EDM)
process.A Box-Behnkin design of response surface methodology is adopted to collect data for analysis.
Regression analysis is conducted to develop equations relating responses with process parameters. Finally, non-
dominated sorting genetic algorithm is used to obtain pareto optimal solution for multi objective optimization.
[2]
According to S.N. Joshi, S.S. Pande, “Thermo-physical modeling of die-sinking EDM process” This
paper reports the development of a thermo-physical model for die-sinking electric discharge machining (EDM)
process using finite element method (FEM). Numerical analysis of the single spark operation of EDM process
has been carried out considering the two-dimensional axi-symmetric process continuum.[3]
According to C.K.Biswas, “Thermal-Electrical Modelling of Electrical Discharge Machining Process”
In the present work, the Joule heating factor was used to model the EDM process and predict the maximum
temperature reached in the discharge channel. From the temperature distribution the volume of material
removed from the work piece and Rmax was estimated. Experiments were conducted with different pulse on-
time (Ton) and current values and the material removal rate was calculated.[4]
III. Problem Statement and Objective
In EDM process, the pulse on time, peak current and Voltage are very important machining parameters
because it can control material remove rate. However, there are difficulties to determine the optimum machining
parameter to increase the material remove rate. The unsuitable pulse duration and peak current will increase the
cost of production. Besides that, adding the dielectric fluid flushing process will increase the material remove
rate. In this study, we will determine the optimum machining parameters to increase material remove rate.To
calculate Material removal Rate (MRR) of OHNS Die steel in order to get accuracy/ surface integrity of
machined work piece
IV. Theoretical Analysis
A.Numerical modeling of the EDM process
To obtain the relationship between pulse conditions and material removal rate, many attempts have
been made to calculate temperature distribution in the electrodes caused by a single pulse discharge by solving
time-dependent heat transfer equations assuming various heat source models. Based on the mathematical
models, the temperature profile due to the passage of an individual pulse can be created.However the scope of
such analysis is limited; a more comprehensive approach is needed.
Joshi and Pande’s Model [3] considers more realistic assumptions for thermal analysis in EDM
process. So it can be considered as best available, realistic and reliable thermal model for the further work of
development in EDM process. Thus this model is the taken as benchmark for the present work of stress analysis.
B.EDM spark
In EDM, the tool (anode) and the work piece (cathode) are immersed in a dielectric medium separated
from each other by a small gap. A controlled spark is generated between the two electrodes by applying a
voltage which breaks down the dielectric medium causing the voltage fall. The on- time of EDM spark (of the
order of microseconds), electrons start flowing from cathode to anode which ionizes the dielectric medium and
form a plasma channel between the cathode and anode. The intense heat generated in the plasma channel melts
and even vaporizes some of the work and tool material causing material removal. The molten metal is held back
at its place due to the large plasma pressure and as soon as the spark on-time is over (the spark collapse) the
dielectric gushes back to fill the void. This sudden removal of pressure results in a violent ejection of the molten
metal from the work surface forming small craters at locations, where material has been removed. [5]
3. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 73 | Page
Fig. 1 Schematic representation of the domain considered for the numerical model
C. Process and boundary conditions
The primary mechanism of material removal in EDM process is the thermal heating of work surface
due to intense heat generated by the plasma, which raises the temperature of the electrodes (tool, work) beyond
their melting point, sometimes even the boiling point. During the process, spark discharges may occur over
work surface at locations where the inter electrode gap is minimum. Figs. 1 and 2 show the two-dimensional
axi-symmetric process continuum and the associated boundary conditions taken for the analysis. Following
assumptions have been made during the thermal Analysis.
Assumptions
1. Work piece and tool materials are homogeneous and isotropic in nature.
2. The material properties of the workpiece and tool are temperature dependent.
3. During the EDM operation, heat is transferred from plasma to electrodes by conduction and radiation, while
from plasma to dielectric by convection and radiation. In the present work, the primary mode of heat
transfer between plasma and electrodes is considered to be conduction.
4. EDM spark channel is considered as a cylindrical column and the spark radius is assumed to be a function
of discharge current and time.
5. Gaussian distribution is taken for heat flux. The influence of the spark zone is taken to be axi-symmetric in
nature.
6. Out of total spark some of total spark energy is dissipated as heat into the work piece, the rest is lost into the
dielectric convection and radiation.
7. Flushing efficiency is considered as 100%. On the machined surfaces there is no deposition of recast layer.
Fig. 2 Process continuum and boundary conditions
D. Governing equation
For the transient, non-linear thermal analysis of EDM process, Fourier heat conduction equation is taken as the
governing equation 1
1
𝑟
𝜕
𝜕𝑟
𝐾𝑡 𝑟
𝜕𝑇
𝜕𝑟
+
𝜕
𝜕𝑧
𝐾𝑡
𝜕𝑇
𝜕𝑧
= 𝜌𝐶 𝑃
𝜕𝑇
𝜕𝑡
(1)
4. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 74 | Page
Where r and z are the coordinates of cylindrical work domain; T is temperature; Ktis thermal
conductivity; ρis density and Cpis specific heat capacity of work piece material. Fig. 2 shows the applied
boundary conditions applied. In EDM machining process, the work piece is immersed in dielectric medium; the
temperature of the domain is thus assumed to be ambient temperature (ta) to start with. The top surface of the
workpiece is in contact with the dielectric medium at (boundary 2).On this surface the Heat flux (q) boundary
condition is applied.
Heat input
The factors which contribute to the accurate calculation of the MRR in single spark EDM model
include the radius of plasma spark, amount of heat input and the thermo-physical properties of material. These
models are simplistic in actual practice neither isthere any uniform application of heat on the work piece nor is
there a point heat source. At the cathode electrode a spark radius exists. Consideration of average thermo-
physical material properties and constant EDM spark radius make the available models simplistic and less
accurate in predictions.
The Gaussian distribution of heat flux input has been used to approximate the heat from the plasma. Due to
EDM spark is given by the heat q entering the workpiece,
𝑞(𝑟) = 𝑞 𝑜 𝑒𝑥𝑝 −4.5
𝑟
𝑅 𝑝𝑐
2
(2)
Using this equation, the maximum heat flux can be calculated as under.
𝑞 𝑜 =
4.57𝐹 𝐶𝑉𝐼
𝜋𝑅 𝑃𝐶
2 (3)
where𝐹𝑐is fraction of total EDM spark power going to the cathode; V is discharge voltage; I is discharge current
and 𝑅 𝑝𝑐 is spark radius at the work surface.
Spark radius
Spark radius is an important factor in the thermal modeling of EDM process. In practice, it is extremely
difficult to experimentally measure spark radius due to very short pulse duration of the order of few
microseconds. The equations proposed by these researchers are not realistic in nature as the EDM spark is
controlled both by discharge energy and discharge on-time have derived a semi-empirical equation of spark
radius termed as ``equivalent heat input radius'' which is a function of discharge current, I (A) and discharge on-
time, 𝑡 𝑜𝑛 𝜇𝑠 Eq. (4)). It is more realistic when compared with the other approaches.
𝑅 𝑝𝑐 = 2.04𝑒 − 3 𝐼0.43
𝑡 𝑜𝑛
0.44
𝜇𝑚 (4)
In the present work, this approach has been used to calculate the equivalent heat input at cathode using
Eqs. (2) and (4). The heat flux equation derived and used for further analysis in this work is,
𝑞(𝑡) =
3.4875×105 𝐹 𝐶 𝑉𝐼0.14
𝑡 𝑜𝑛
0.88 𝑒𝑥𝑝 −4.5
𝑡
𝑡 𝑜𝑛
0.88
(5)
Where𝐹𝑐 is the fraction of total power going to the cathode; V is the discharge voltage; I is the
discharge current; t is the time 𝜇𝑠 and 𝑡 𝑜𝑛 is time 𝜇𝑠 at the end of electric discharge. Eq. (5) controls the
amount of heat which is applied on the cathode which in turn, causes removal of material from cathode during
operation.
The governing equation (Eq. (1)) with boundary conditions outlined earlier was solved by FEM to
predict the temperature distribution at the end of each transient heat transfer analysis cycle. ANSYSTM16.0, a
FEM solver was used. A two-dimensional continuum of size ten times the spark radius was considered for the
analysis. Four-noded, axi-symmetric, thermal solid element (PLANE 55) was used for discretization of the
continuum. The transient heat transfer problem was solved by applying the heat flux at the spark location (Eq.
(5)) and using the discharge duration as the time step for the analysis. Fig. 7 shows the results for a typical
problem showing the temperature contour plots. The results are for work material OHNS END31 die tool steel
with machining conditions discharge current 6 A, discharge voltage 40 V and discharge duration of 30
s .
Table I: Maximum heat flux over the spark radius
Sr No Current ( Ip) Pulse ON (time) Voltage Q in for Analysis
1 6 75 40 4834.914965
From the calculations of maximum heat flux over the spark radius we have calculated the heat flux for case 1 as
4834.9 W/mm2.
5. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 75 | Page
Results for the case 1 while modelling the complete workpiece plate (OHNS) En31 of Size 100mm
×80mm×16mm. Minimum Meshing size is limited by the large geometry that we have to mesh. So minimum
Mesh size used is 0.1 mm.
Plane Axisymmetric modelling approach is used from ANSYS 16. Below are the images of axisymmetric
geometry and meshing with some results plots.
Fig.3 - Axisymmetric Sketch for Work Piece Complete
Fig4: - Loading Condition for Thermal Transient Analysis
Table II:Loading condition
Time Q ( W/mm2
)
0 3301
7.50E-05 3301
2.3E-04 0
7. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 77 | Page
Results plots for the same is shown below
Fig7: Temperature Distribution Plot case 1
From Above FEA plot it is clear that we can reduce the size of the sample material taken to very small
dimensions. For next analysis we will consider only 2 mm radius and 2 mm height cylinder, represented by
axisymmetric model of 2 mm square geometry. From next case melting temperature for SS431 material is
1540ᴼC we need to calculate the volume removed in single on off cycle to get Volume removal rate
V. Finite Element Analysis
To calculate the material removal due to single spark discharge, the cavity volume was divided into
number of cylindrical discs (Fig. 8). The x-y coordinates of the node boundary are calculated from ANSYS
WORKBENCH file.
Fig.8:Calculation of crater volume
8. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 78 | Page
Total crater volume𝐶𝑣𝑡 𝑚𝑚3
is given by,
𝐶𝑣𝑡= 𝐷𝑖
𝑛−1
𝑖=0 (6)
Where volume of a disc, 𝐷𝑖is given by,
𝐷𝑖 = 𝜋
𝑋 𝑖+𝑋 𝑖+1
2
2
𝑦𝑖+1 − 𝑦𝑖 (7)
Where x and y are the coordinates of nodes and n is the number of nodes. Eqs. (6) and (7) were used to calculate
the crater volume generated by a single spark discharge. MRR was computed for chosen process conditions
considering that all sparks are equally effective with 100% dielectric flushing efficiency. The MRR 𝑚𝑚3
/
𝑚𝑖𝑛 is computed by,
𝑀𝑅𝑅 =
60×𝐶 𝑣𝑡
𝑡 𝑜𝑛 +𝑡 𝑜𝑛
(8)
Table III.MMR for Case I
Node No X(mm) Y(mm) Di 𝐶𝑣𝑡 MMR
1 0.00000E+00 1.98800E+00 1.41372E-07 7.28177E-05 14.56
2 1.50000E-02 1.98880E+00 7.12513E-07
3 2.10000E-02 1.98950E+00 1.26669E-06
4 2.70000E-02 1.99020E+00 2.15026E-06
5 3.15000E-02 1.99100E+00 2.50493E-06
6 3.60000E-02 1.99170E+00 3.53429E-06
7 3.90000E-02 1.99250E+00 3.60710E-06
8 4.20000E-02 1.99320E+00 4.75574E-06
9 4.50000E-02 1.99400E+00 1.05207E-05
10 4.95000E-02 1.99550E+00 1.26201E-05
11 5.40000E-02 1.99700E+00 6.59198E-06
12 5.55000E-02 1.99770E+00 2.44120E-05
13 6.07500E-02 2.00000E+00
Where 𝐶𝑣𝑡the material is removed per discharge pulse;𝑡 𝑜𝑛 is discharge duration and𝑡 𝑜𝑓𝑓 is the discharge
off-time. T on time is 75 microseconds and T off time is 225 microseconds Actual reading recorded from
machine was 13 𝑚𝑚3
/min.
Table IVMMR for Case I
Exp. No Discharge current
(A)
Pulse ON time
(µs)
Pulse OFF time
(µs)
Voltage MRR MRR BY ANSYS Error %
6 75 225 40 13.27 14.56 9.75%
9.75% error is observed in case 1 for sample case all the calculations are displayed for first case. For rest of the
cases temperature plots and table for the values will be provided directly.
Fig 9: Temperature Distribution Plot case 2
9. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 79 | Page
Fig. 10Temperature Distribution Plot case 3
Fig 11: Temperature Distribution Plot case 4
Fig 12: Temperature Distribution Plot case 5
10. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 80 | Page
Fig 13: Temperature Distribution Plot case 7
Fig 14: Temperature Distribution Plot case 8
Fig15: Temperature Distribution Plot case 9
11. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 81 | Page
Table VMMR for all Case
Exp.
No
Discharge current
(A)
Pulse ON time
(µs)
Pulse OFF
time (µs)
Voltage MRR
(from machine
manual)
MRR BY
ANSYS
Error %
(mm3/mm)
1 6 75 225 40 13.27 14.56 9.75
2 6 100 250 45 21.75 23.5 8.07
3 6 150 450 50 25.04 29.33 17.13
4 8 75 225 45 20.19 20.85 3.27
5 8 100 250 50 37.82 43.11 13.98
6 8 150 450 40 35.55 39.47 11.02
7 12 75 225 50 45.7 47.5 3.94
8 12 100 250 40 52.33 58.37 11.55
9 12 150 450 45 52.52 57.43 9.35
VI. Experimental Analysis
A.Machine tool
Experiments are carried out using CNC EDM (EMT 43) (Electronica) die sinking machine (shown in
fig 3.2). Table 3.2 shows the specification of die sinking EDM machine.
Table VMMR for all Case
Machining Conditions
Machine Used EDM (model 5535) (Electronica)
Electrode Electrode Copper (99.9% Purity)
Electrode Polarity Positive
Work piece Oil Hardened Non Shrinking Steel (48-50 Rc)
Dielectric EDM Oil
Flushing Condition Pressure Flushing through 6 mm hole through work piece
B. Work piece material
OHNS (EN 31) PLATE tool steel Size of 100mm ×80mm ×16mmlength size has been used as a work
piece material for the present experiments. The chemical composition and mechanical properties of the work-
piece materials are shown in Table VI and Table VII
Table ViChemical composition of EN 31 Tool Steel
Electrode Chemical composition (wt. %)
C 1.07
Mn 0.58
Si 0.32
P 0.04
Si 0.03
Cr 1.12
Fe 96.84
Table ViiMechanical properties of EN 31 Tool Steel
EN 31 Tool Steel
Thermal Conductivity 𝑤/𝑚𝑘 46.6
Density 𝑔𝑚/𝑐𝑐 7.81
Electrical Resistivity 𝑜𝑚𝑐𝑚 0.0000218
Specific heat capacity (j/gm.-℃ 0.475
Fig16: Work piece material before machining
12. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 82 | Page
Fig17: Work piece material after machining
C.Electrode material
An electrolytic pure copper with 12 mm X 30 mm is used as a tool electrode (positive polarity). Copper shows
good response in metal removal rate toward high values of discharge current, due to increase in thermal
conductivity and electrical conductivity of copper. The mechanical properties of the tool materials (electrode)
are shown in Table VIII.
.Table ViiiMechanical properties of Electrode
Copper (99% pure)
Thermal Conductivity 𝑤/𝑚𝑘 391
Density 𝑔𝑚/𝑐𝑐 1083
Electrical Resistivity 𝑜𝑚𝑐𝑚 1.69
Specific heat capacity (j/gm-℃ 0.385
Table IxDifferent variables used in the experiment and their levels
Response Material Removal Rate (mm3 /min.)
Parameters Tool Wear Rate (mm3 /min.)
Surface Roughness (µm)
Control Parameters Levels
1 2 3
Discharge current (A) 6 8 12
Pulse ON time (µs) 75 100 150
Voltage 40 45 50
D.Experimental results
The material removal rate found in the experiment conducted with varying 𝑇𝑜𝑛 and current values are
shown in Table X. The difference in weights, volume of material removed and material removal rates are
also presented in the table.
Table XMaterial removal rate found in the experiment conducted with varying 𝑇𝑜𝑛 and current values
SN Discharge current
(A)
Pulse ON time
(µs)
Voltage Material Removal Rate (experiment) MRR
MRR BY
ANSYS
(mm3/mm)
1 6 75 40 12.75 14.56
2 6 100 45 20.22 23.5
3 6 150 50 24.78 29.33
4 8 75 45 21.52 20.85
5 8 100 50 38.42 43.11
6 8 150 40 37.58 39.47
7 12 75 50 49.23 47.5
8 12 100 40 60.96 58.37
9 12 150 45 58.53 57.43
Sample Calulation:
For Ton=75, the Material removal rates at 4 different current values are:
Current = 6 Amperes
The initial weight of the sample=580.43 grams
After machining, the final weight=580.001 grams
13. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 83 | Page
Weight loss = 580.43-579.229 (grams) = 1.201 grams
Volume Loss = Weight loss/Density
= 1.201/0.00785
=152.99𝑚𝑚3
Material Removal Rate = Volume of the material removed/Time = 152.99/12
=12.75 mm3/min.
Fig. 18 Experimental setup
Fig. 19 EDM machine View
14. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 84 | Page
VII. Intelligent process modeling using ANN
Artificial Neural Network (ANN) is well known due to their ability to approximate non-linear and
complex relationship between process parameters. It was, therefore, thought appropriate and convenient to
develop a comprehensive (4 inputs – 1 output) EDM process model using ANN for quicker and accurate
prediction of process performance results. A comprehensive process model of EDM was developed using ANN
to accurately predict the process responses viz. MRR.
Table XMaterial removal rate found in the ANN Process modelling
SN Discharge current
(A)
Pulse ON time
(µs)
Voltage Material Removal Rate (experiment) MRR
MRR BY
ANN
(mm3/mm)
1 6 75 40 12.75 12.79
2 6 100 45 20.22 20.43
3 6 150 50 24.78 24.75
4 8 75 45 21.52 19.75
5 8 100 50 38.42 35.57
6 8 150 40 37.58 37.59
7 12 75 50 49.23 49.23
8 12 100 40 60.96 60.95
9 12 150 45 58.53 58.54
VIII. Results and Discussion
Fig20: Comparisons between Experimental MRR, FEM and ANN calculated MRR
Taking En-31 (OHNS) as workpiece material with single spark the results have been obtained. From
Table X, it clear that the values of the responses predicted by numerical model are closer to the experimental
results. Thus, it can be concluded that the numerical model would give better prediction of process responses
compared to the earlier reported models. Temperature distribution in the workpiece has been shown in Fig. 7.
From the simulation result it is clear evident that at the center line, on the top surface of the workpiece highest
temperature generates. The high temperature rises during the spark on time can easily melt the material and
formed a dome in the work piece. This is evident from the temperature distribution after material removal in
FEA model as shown in Fig. 8. The volume of metal remove depends on amount of heat energy induced in the
material. Therefore the MRR increase in both increase in current and voltage. Fig 20 shows the graphical
representation of MRR obtained in FEM model and experimentally. Experimental result is almost equal to the
predicted MRR obtained by FEM model.
IX. Conclusion
In the present a numerical approach is presented in this work to estimate material removal rate on work
piece in EDM process. The results obtained by numerical analysis and experimental methods have been
compared. It can be concluded that numerical method provides reasonably accurate estimation of responses.
Therefore, the method can be adopted to predict the responses before going for actual cutting operation. It may
save time and cost of experimentation work. For developing such model various important process parameters
are taken into account such as pulse on/off time, material properties, shape and size of heat source and heat
15. Predicting Optimized EDM Machining Parameterthrough Thermo Mechanical Analysis
DOI: 10.9790/1684-1303057185 www.iosrjournals.org 85 | Page
energy given as input to the work piece. The proposed model can be used for selecting ideal process states to
improve EDM process efficiency and finishing capability.
Acknowledgment
I take this opportunity to thanks Prof A. B. Gaikwad and Prof. A. N. Patil for valuable guidance and for
providing all the necessary facilities, which were indispensable in completion of this work. Also I sincerely
thanks to all the authors who worked on optimization of EDM process.
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