OPTIMIZATION OF WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
OPTIMIZATION OF WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Characterization of metals machined using EDM.
Machining on materials - SS304, D2 ; EDM Machine - Sparkonix SN25 ; Study on MRR, Hardness, Roughness, Grain Size with Voltage, Current, Lift as working parameters.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
electrochemical discharge machining.
also known as electrochemical spark machining.
we covert normal drilling machine in electrochemical spark machining and perform drilling operation on the work piece and create a macrohole in a quartz glass. the results are shown in the ppt.
we created this project under the head of department of mechanical engineering ER. Rakesh sigh sir and ER.mudit tyagi sir from mtech department from noida institute of engineering and technology, greater noida.
Experimental Study of Surface Parameters of EN31 on Powder Mixed EDM using Ta...ijsrd.com
PEDM has become an effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is EN 31 taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are type of powder, current, pulse on time and powder concentration. Taguchi method is applied to create an L18 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR) and Surface Roughness (SR) is studied and investigated. The tool material is copper. All the calculations are made with the help of MINITAB 16 software. Dielectric used for experimentation is kerosene. Two powders silicon carbide and boron carbide of 70 mesh is used. Most influence factor for MRR observed is powder concentration with 49.12 % contribution. For SR peak current with contribution of 43.4 % plays a n important role.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
Characterization of metals machined using EDM.
Machining on materials - SS304, D2 ; EDM Machine - Sparkonix SN25 ; Study on MRR, Hardness, Roughness, Grain Size with Voltage, Current, Lift as working parameters.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
electrochemical discharge machining.
also known as electrochemical spark machining.
we covert normal drilling machine in electrochemical spark machining and perform drilling operation on the work piece and create a macrohole in a quartz glass. the results are shown in the ppt.
we created this project under the head of department of mechanical engineering ER. Rakesh sigh sir and ER.mudit tyagi sir from mtech department from noida institute of engineering and technology, greater noida.
Experimental Study of Surface Parameters of EN31 on Powder Mixed EDM using Ta...ijsrd.com
PEDM has become an effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is EN 31 taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are type of powder, current, pulse on time and powder concentration. Taguchi method is applied to create an L18 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR) and Surface Roughness (SR) is studied and investigated. The tool material is copper. All the calculations are made with the help of MINITAB 16 software. Dielectric used for experimentation is kerosene. Two powders silicon carbide and boron carbide of 70 mesh is used. Most influence factor for MRR observed is powder concentration with 49.12 % contribution. For SR peak current with contribution of 43.4 % plays a n important role.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
MODELING AND OPTIMIZATION OF EDM PROCESS PARAMETERS: A REVIEWIAEME Publication
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermo electric energy between the work piece and an electrode. There are different input parameters which influence on the outputs such as MRR, TWR and SR.
Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, which is an essential need for industries towards manufacturing of quality products at lower cost.
Electric discharge machining with analysis of variancePBR VITS
It defines and clarifies the experimental investigation on HSS steel material by using die sinker EDM.It is very helpful to the users who are waiting for the experimental analysis of the readings which is taken.
Machinability evaluation of cryogenically tempered die steel in electric disc...eSAT Journals
Abstract Electrical discharge drilling (EDD) is a well-known machining alternative for creating geometrically obscure shapes in die steel. Cryogenic temper of work and electrode material is innovative technology in the field of EDD. Work in hand investigates the effect of cryogenic tempering of AISI D2 steel (workpiece) and copper electrode (tool) on material removal rate (MRR) in EDD based on design of experiments approach. The discharge current, pulse-on-time and electrode-workpiece combination (cryogenically tempered or untempered) are the parameters selected for this study. The orthogonal array, signal-to-noise ratio (S/N) and analysis of variance (ANOVA) are used to find out the effect of cryogenic tempering on MRR. The results obtained demonstrate that the discharge current and pulse-on-time are the major parameters influencing the MRR for all samples, followed by electrode-workpiece combination i.e. cryogenic tempering of electrode and workpiece. Cryogenic tempering is found to have significant effect (nearly 10%) on MRR. It is recommended to cryogenically temper both the electrode and workpiece to maximize the MRR. Index Terms: Electric discharge drilling, Cryogenic tempering, Die steel, copper electrode
OPTIMIZATION OF PROCESS PARAMETERS IN DIRECT METAL DEPOSITION TECHNIQUE USING...IAEME Publication
Direct Metal Deposition (DMD) process is an important component in many industrial operations. The DMD parameters are the most important factors affecting the quality, productivity and cost of metal depositin. This paper presents the influence of DMD parameters like Laser power, laser scan speed, powder mass flow rate on height deposition in DMD. A plan of experiments based on Taguchi technique has been used to acquire the data. An Orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are employed to investigate the DMD characteristics & optimize the height deposition. Finally the conformations tests have been carried out to compare the predicated values with the experimental values confirm its effectiveness in the analysis of penetration
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
it is a presentation on electrical discharge machining which is new method for machining hard conductive materials which are difficult to machine with old technique of machining. it does not cause wear of tool.
Optimization of edm for mrr of inconel 600 using taguchi methodsushil Choudhary
Electrical discharge machining (EDM) process is convert electrical energy into heat energy between the work piece and tool electrode in the presence of dielectric fluid like, EDM oil, to process conductive difficult-to-machine materials. EDM process is has been applicable in the machining of hard, brittle and all kinds of electric conductive materials. This process widely used for produces die making, mould making, complex shapes, deep holes and other geometrical shapes as per desire. Inconel 600 super alloy materials widely used in various types of industries such as: aerospace, aircraft, nuclear, food processing, pulp manufacturing, automobiles industry etc. In this study, investigations on the effect of process parameters on machining of Inconel 600 super alloy material. Tungsten carbide material used as tool electrode and EDM oil used as dielectric fluid. The effects of input process parameters such as pulse-on-time, peak current and gap voltage on performance measure material removal rate was investigated using Taguchi method. MRR is lineally increases with the increase in peak current during the EDM process. MRR is increases with the increase in gap voltage. Initially MRR increases with increase in pulse on time then decreases with the increase of pulse on time.
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.
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.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
EXPERIMENT INVESTIGATION OF EDM PARAMETER MRR AND TWR WITH MULTI WALL CARBON ...IAEME Publication
Electric discharge machining is non conventional machining process used for machining of hard materials which cannot be machined by conventional machining process. Electric discharge machining is an electro sparking method of metal working involving an electric erosion effect. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporizing.
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
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.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
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2. Optimization of Electrical Discharge Machining of
Composite 90WC-10Co Base on Taguchi Approach 427
from the work piece at a controlled rate. Thus, the material is removed by a succession of electrical
discharges that, occur between the electrode and the work piece. During the EDM process, the work
piece and the electrode are submerged in dielectric fluid oil, which is an insulator that helps to control
the arc discharge. The dielectric oil, which provides a means of flushing, is pumped through the arc
gap between electrode and the work piece. This process removes suspended particles of the work piece
and the electrode form the work area. The schematic diagram of EDM is shown Fig. 1, along with the
procedure for dielectric flushing. EDM is one of the non-traditional machining techniques widely used
to manufacture harder materials for the automotive, aerospace, and surgical, moulds and dies (Ponappa
et al., 2010). Therefore, the EDM technique is an essential approach for mould and die making
industries to fabricate their products with superior performance and accuracy (Lin et al., 2009). This
machining process produces tools with complex shapes and is extensively used in industrial settings.
EDM can operate as a surface finish in the last stage of tool production (Singh et al., 2004). Tungsten
carbide (WC-Co) is an important tool and die material mainly because of its high hardness, strength
and wear resistance (Mahdavinejad and Mahdavinejad, 2005). Due to its high melting point of 2870 oC,
WC-Co cannot be processed easily by conventional machining techniques. The principle of the EDM
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solid, liquid, or gas (Mukherjee and Ray, 2006). Currently, an insulating material can be machined
with EDM using assisting electrode (Fukuzawa et al., 2004). Muttamara et al. (2003) studied the
probability of precision micro-machining of insulating Si3N4 ceramics by the EDM process.
Copper-tungsten electrodes are important in machining small holes in the EDM process.
Therefore the EDM process will open up an opportunity for the machining of tungsten carbide.
Tungsten carbide is a type of cemented carbide, in which particles of carbide such as WC-Co and
titanium carbide (TiC) are bonded the process of powder metallurgy. In tungsten carbide, small cobalt
particle, approximately 1-10 µm, are used as binders (Puertas et al., 2004). Microcracks are observed
on the surface of tungsten carbide work piece when they are machined with EDM. Because of their
lower melting point, cobalt particles can melt and separate away from tungsten carbide and result in
microcracks. When the work piece is used as a mould or tool, an important consideration is the product
lifespan. Singh et al. (2004) studied the effects of material removal rate (MRR), electrode wear ratio
(EWR), surface roughness (SR), and diametral overcut of grade EN-31 cutting tool steel, when used as
an electrode material. The experimental results showed that an increasing current could increase MRR,
SR, and diametral overcut. The best electrode is copper due to its maximum MRR, minimum EWR,
SR, and over-cut. Lee and Li (2001) researched the effects of electrode material in machining tungsten
carbide by comparing copper, graphite, and copper tungsten electrode. The results showed that copper
tungsten had the highest MRR and the lowest EWR.
In an EDM operation, optimizing sparking performance requires the use of correct parameters.
However, choosing the correct parameters often calls experience, an instruction manual or a large
number of experiments that can consume both material and time. The Taguchi method solves this
problem by using specially designed orthogonal arrays. The process parameters can be studied with a
minimum number of experiments (Wang et al., 2000). Recently, the Taguchi method was widely
employed in several industrial field and research applications. Mahapatra and Patnaik (2006) used this
method to optimize the process parameters of wire electrical discharge machining (WEDM). Marafona
and Araujo (2009) used this method to study the influence of work piece hardness on EDM
performance. Their results show that the work piece hardness and its interaction influence the MRR
and the SR of the work piece. Prihandana et al. (2009) studied the effect of micro-powder suspension
and ultrasonic vibration of dielectric fluid in micro-EDM process, while. Sundaram et al. (2008)
studied the process parameters of ultrasonic assisted micro-EDM using the Taguchi approach as well.
Tzeng and Chen (2007) reported the application of fuzzy logic analysis coupled with Taguchi method
to optimize the precision and accuracy of the high-speed EDM process. Gaitonde et al. (2008)
presented the application of the Taguchi optimization method for simultaneously minimizing burr
height and burr thickness with respect to the influence of cutting drill and geometry. Kao et al. (2009)
3. 428 Pichai Janmanee and Apiwat Muttamara
optimized the EDM parameters with multiple quality characteristics on machining Ti-6Al-4V based on
the Taguchi method. Lin et al. (2009) showed grey relational analysis is more straight forward than the
fuzzy Taguchi method for optimizing the EDM process with multiple process responses.
The objective of this research was to use the Taguchi method to study the performance of the
EDM process on machining tungsten carbide. The most important performance measures in EDM were
material removal rate (MRR), electrode wear ratio (EWR) and microcrack density (Cr.S.Dn) on the
work piece surface.
Figure 1: The schematic diagram of EDM
2. Experimental Methods
2.1. Experimental Materials
Tungsten carbide was selected as the work piece for this research. The sample had 10% cobalt with
90% tungsten carbide and was bought from United Tungsten Co., Ltd. Tungsten carbide is a class of
hard material composite. It is widely used as a tool material in a variety of applications where the
demands on hardness and toughness are high. The essential properties of the work piece material are
shown in Table 1. The work piece had a diameter of 25 mm and thickness of 20 mm. The graphite
electrode (EDM-3) purchased from Poco Graphite (Thailand) Co., Ltd. was made from powders
produced by the semi-sintering process. The electrode was 3 mm in diameter and 50 mm in length, and
it was held on the spindle chuck of the EDM machine. Table 2 shows the essential properties of the
electrodes. The dielectric oil used in this investigation was Shell EDM Fluid 2A from Shell Co., Ltd.
(Thailand).
Table 1: Essential properties of tungsten carbide
Essential properties Description
Melting point (oC) 2,870
Density (g/cm3) 15.7
Thermal expansion (oC) 5x10-6
Hardness (HRA) 87.4
Elastic modulus (Gpa) 648
Electrical resistivity ( cm)
・ 17×10-6
Thermal conductivity (W/mK) 63
Table 2: Essential properties of graphite electrodes (EDM-3)
Essential properties Description
Melting point (oC) 3,350
Density (g/cm3) 1.81
Average particle size (µm) <5
Electrical resistivity ( cm)
・ 1.491×101
4. Optimization of Electrical Discharge Machining of
Composite 90WC-10Co Base on Taguchi Approach 429
Table 2: Essential properties of graphite electrodes (EDM-3) - continued
Flexural strength (kg/cm2) 950
Compressive strength (kg/cm2) 1,500
2.2. Experimental Procedures
The experiments were performed on a numerical control model EDM-FORM-2-LC manufactured by
Charmilles Technologies Corporation. A negative polarity electrode with depth of cut of 3 mm was
used. The machining parameters such as MRR (mm3/min), EWR (mm3/min), and Cr.S.Dn were varied
to determine the most important parameters that could affect performance characteristic. The MRR of
the work piece was measured by dividing the weight of the work piece before and after machining by
the machining time. The EWR in this study was defined by the ratio of the electrode weight to the
work piece weight and expressed as a percentage. Similar procedures for measuring the weight of the
work piece have been used to determine the weight of the electrode before and after machining
(Tomadi et al., 2009). Microcrack density on finished surfaces of work piece in the EDM process is an
important measurement of defects in the material (Lee and Li, 2003).
The microcrack density on the work piece surface can be measured by (O’Brien et al., 2003):
(1) number of microcrack per area, or numerical crack density per area, Cr.Dn (no. of crack/mm2): (2)
total length of microcrack per area, or surface crack density, Cr.S.Dn (µm/mm2); and (3) mean crack
length, Cr.Le (µm). In this research, measuring technique 2 was selected because the work piece
contained cracks of various widths. The unit of measurement was µm/0.05 mm2. The values of visually
measured microcrack width multiplied by the weight factor are shown in Table 3. For this experiment,
the EDM process parameters studied were as follows polarity, on time, off time, open-circuit voltage,
discharge current and electrode material. The detailed experimental conditions used in this
investigation are shown in Table 4. Finally, the optimal EDM parameters of material removal rate,
electrode wear ratio, and microcrack density were determined by the Taguchi method.
Table 3: Weight factor of width of microcracks (Cr.S.Dn) measurement
Width (µm) Weight factor(x)
Less than 3.23 1
3.23-6.45 2
6.45-9.68 3
9.68-12.90 4
12.90-16.13 5
Table 4: Experimental conditions
Working conditions Descriptions
Work piece 90WC-10Co
Electrode EDM-3
Polarity Nagative (-)
On-time 25 µs
Off-time 2,510,1600 µs
Open circuit voltage 90,150,250 V
Discharge current 1.5,38,75 A
Dielectric fluid Oil (Shell fluid 2A)
2.3. Procedure for the Taguchi Approach
The Taguchi method is statistical method developed by Genichi Taguchi to improve the quality of
manufactured goods. More recently has been applied to the field of (Rosa et al., 2009) engineering,
biotechnology, marketing and advertising (Sreenivas et al., 2004). The method consists of a plan to
acquire data from experiments in a controlled way, and to obtain information about the behaviour of a
5. 430 Pichai Janmanee and Apiwat Muttamara
given process (Ponappa et al., 2010). There are three characteristics of the Taguchi methodology:
smaller-the-better, larger-the-better, and nominal-the-best. In general the Taguchi method provides a
significant reduction in the size of experiments with considerable savings in time and cost, thereby
acclerating the experimental process (Sundaram et al., 2008; Lajis et al., 2009). Fig. 2 shows the
Taguchi method applied to the experimental procedures step. In this research, the Taguchi method was
used to determine optimal machining to parameters maximize MRR and minimize EWR, as well as
Cr.S.Dn in the EDM process. The method uses orthogonal arrays (OA) and calculates signal-to-noise
(S/N) ratios. In the L9 (33) orthogonal array design, three columns and nine rows set up three individual
levels. The first column was assigned to the discharge current (A), the second column to off-time (B),
and the third column to open-circuit voltage (C). In addition to the S/N ratio, a statistical analysis of
variance (ANOVA) was also employed to indicate the impact of process parameters. To calculate the
S/N ratio, the HB value for “the higher the better” and LB value for “the lower the better” were first
determined by equations (1), (2), and (3):
1 n 1
HB = ∑ 2
n i =1 y MRR (1)
1 n 1
LB = ∑ 2
n i =1 y EWR (2)
n
1 1
LB = ∑ y2
n i =1 Cr .S . Dn (3)
where y MRR , y EWR and yCr .S . Dn are material removal rate, electrode wear ratio and surface crack
density, respectively. n is the number of experiments in the trial, beginning with the ith experiment.
The S/N ratio can then be calculated as a logarithmic transformation of the loss function, as shown in
equations (4), (5), and (6):
S N ratio for MRR = −10 log ( HB ) (4)
10
S N ratio for EWR = −10 log10 ( LB ) (5)
S N ratio for Cr.S.Dn = −10 log 10 ( LB ) (6)
Figure 2: Taguchi method of procedure step
Table 5 shows the experimental values of the Taguchi approach on EDM machining control
parameters and the levels of machining parameters according to the S/N ratio.
6. Optimization of Electrical Discharge Machining of
Composite 90WC-10Co Base on Taguchi Approach 431
Table 5: Machining parameter of tungsten carbide
Levels
Symbol Control parameters Observed values
I II III
A Discharge current (A) 1.5 38 75 MRR (mm3/min)
B Off time (µs) 2 510 1600 EWR (%)
C Open circuit voltage (V) 90 150 250 Cr.S.Dn (µm/mm2)
3. Results and Discussions
The experimental results of each set of input parameters in the L9 orthogonal array are given in Table
6. The table also contains a detailed list of MRR, EWR and Cr.S.Dn correlated with each experimental
measurement of the EDM process on the composite WC-Co. Data analysis was done using the
MINITAB software, version 14.
Table 6: Experimental results of L9 orthogonal array
Parameters Response
Order
A B C MRR EWR Cr.S.Dn
1 1 1 1 0.163 455.217 346.13
2 1 2 2 0.084 365.667 183.87
3 1 3 3 0.125 275.550 460.97
4 2 1 2 0.540 355.556 954.84
5 2 2 1 0.281 287.143 1119.36
6 2 3 3 0.238 237.143 885.48
7 3 1 3 2.731 276.460 1459.68
8 3 2 1 1.730 87.360 1024.84
9 3 3 2 1.472 37.234 1056.45
3.1. Analysis of MRR
For the S/N ratio of MRR with larger-the-better algorithm, the results showed that discharge current
(A) had an effect on MRR. The experimental data analysed by ANOVA showed that discharge current
had an effect on MRR as well, at the 95% confidence level. Tables 7, 8 and Fig. 3 show a list of the
corresponding ANOVA results, where the contribution of each parameter is calculated. For the relation
between discharge current and MRR of work piece were found that an increased current have influence
to increasing MRR. That means, though a higher current causes more removal work piece material.
The optimal parameters for maximum MRR, as predicted by the MRR results were as follow:
discharge current of 75 A, on-time of 2 µs, and open-circuit voltage of 250 V. These values were
chosen because mean of the predicted values were similar to the experimental values of 2.531 and
2.731, as shown in Table 6.
3.2. Analysis of EWR
Tables 9 and 10 show the orthogonal array based on experimental results of electrode EWR and their
corresponding S/N ratio. The analysis of EWR with smaller-the-better algorithm revealed that
discharge current (A) and off-time (B) had an influence on EWR. Fig. 4 shows the main effect of EWR
of each factor for various level condition. According to Fig. 4, the EWR decreases with the two major
parameters, A and B. Moreover, to observed that mean the machining voltage (negative polarity),
maximum discharge current, and off-time may imply a smaller EWR (Lajis et al., 2009). Therefore, the
ANOVA results indicated that discharge current (A) significantly affected EWR and also off-time, at
the 95% confidence level. P-value of off-time (B) was 0.082 close to therefore the off-time
factor was shown to be a risk factor to EWR as well. Since P-values of factors A and B were less than
0.05, they had a statistically significant effect on MRR at the 95% confidence level.
7. 432 Pichai Janmanee and Apiwat Muttamara
Table 7: S/N ratio of MRR
MRR
Factors
I II III Delta
A -18.444 -9.615 5.615 24.059
B -4.127 -9.260 -9.057 5.132
C -7.821 -7.836 -6.787 1.049
Table 8: ANOVA of MRR
Source Df SS MS F P
A 2 6.1281 3.0640 28.21 0.034
B 2 0.4908 0.2454 2.26 0.307
C 2 0.2330 0.1165 1.07 0.483
Error 2 0.2172 0.1086
Total 8 7.0691
Figure 3: Main effect plot of MRR
Main Effects Plot for MRR
Fitted Means
A B
2.0
1.5
1.0
0.5
0.0
Mean
1 2 3 1 2 3
C
2.0
1.5
1.0
0.5
0.0
1 2 3
Table 9: S/N ratio of EWR
EWR
Factors
I II III Delta
A -51.08 -49.23 -39.69 11.38
B -51.01 -46.42 -42.57 8.43
C -46.50 -44.57 -48.93 4.37
Table 10: ANOVA of EWR
Source Df SS MS F P
A 2 84411 42206 19.22 0.049
B 2 49483 24741 11.27 0.082
C 2 1166 583 0.27 0.790
Error 2 4392 2196
Total 8 139452
8. Optimization of Electrical Discharge Machining of
Composite 90WC-10Co Base on Taguchi Approach 433
Figure 4: Main effect plot of EWR
Main Effects Plot for EWR
Fitted Means
A B
350
300
250
200
150
Mean
1 2 3 1 2 3
C
350
300
250
200
150
1 2 3
3.3. Analysis of Cr.S.Dn
Fig. 5 show the main effects of Cr.S.Dn of each factor for various level condition. According to this
figure the Cr.S.Dn increases with high value of discharge current, off-time and open-circuit voltage.
However, the results from the experimental study indicate that when the higher value of process
parameters, had a significant influence on Cr.S.Dn. Because of more electrical energy and thermal into
the machining zone. The analysis of S/N ratio of Cr.S.Dn with smaller-the-better algorithm and
ANOVA revealed that discharge current (A) and open-circuit voltage (C) had a significant influence on
Cr.S.Dn. Since P-values of factor A, B and C were less than 0.05, these factors had a statistically
significant effect on Cr.S.Dn as well, at the 95% confidence level. This is shown in Tables 11, and 12.
Table 11: S/N ratio of Cr.S.Dn
Cr.S.Dn
Factors
I II III Delta
A -49.78 -59.84 -61.33 11.54
B -57.89 -55.49 -57.56 2.40
C -56.65 -55.12 -59.18 4.06
Table 12: ANOVA of Cr.S.Dn
Source Df SS MS F P
A 2 1190691 595345 740.61 0.001
B 2 35634 17817 22.16 0.043
C 2 147944 73972 92.02 0.011
Error 2 1608 804
Total 8 1375877
Table 13: Results of the confirmation experiments
Optimal parameters Optimal parameters Optimal parameters of
Details
of MRR of EWR Cr.S.Dn
Prediction Experimental Prediction Experimental Prediction Experimental
Level A3 B1 C3 A3 B1 C3 A3 B3 C2 A3 B3 C2 A1 B2 C2 A1 B2 C2
Mean 2.53156 2.731 41.5171 37.234 173.262 183.87
9. 434 Pichai Janmanee and Apiwat Muttamara
Figure 5: Main effect plot of Cr.S.Dn
Main Effects Plot for CrSDN
Fitted Means
A B
1200
1000
800
600
400
Mean
1 2 3 1 2 3
C
1200
1000
800
600
400
1 2 3
4. Confirmation Experiments
To verify the improvement of the observed the optimal combination of the machining parameters were
used to perform confirmation experiments (Mahaparata et al., 2006). The estimated S/N ratios were
calculated by equation (7),
n0
η = η m + ∑ (η i − η m )
ˆ
i =1 (7)
ˆ
where η is the estimated S/N ratios for optimal combinations of machining parameters,
η m is the total
mean S/N ratio, η 0 is the number of significant parameters, and η i is the mean S/N ratios at the
optimal level (Lin et al., 2009). The results of the confirmation experiments are shown in Table 13.
The experiment performed at the A3 B1 C3 level of parameters showed that the maximum MRR
increased from 2.531 mm3/min to 2.731 mm3/min. The experiment performed at the A3 B3 C2 level of
parameters showed that the minimum EWR decreased from 41.517 % to 37.234 %. The experiment
performed at A1 B2 C2 level of parameters showed the minimum Cr.S.Dn increased from 173.262
µm/mm2 to 183.870 µm/mm2. In addition, the SEM micrograph in Fig. 7 shows the Cr.S.Dn of the
EDM surface with the orthogonal array parameter A1B2 C2 (a) as the best parameters with microcrack
density per area of 183.870 µm/mm2. The array parameter A3B1C3 (b) was poor with a microcrack
density per area of 1459.68 µm/mm2.
Figure 6: SEM micrographs of Cr.S.Dn on surface EDM a) the best parameters condition : A1 B2 C2, b) the
poor parameters condition : A3 B1 C3
a) A1 B2 C2 b) A3 B1 C3
10. Optimization of Electrical Discharge Machining of
Composite 90WC-10Co Base on Taguchi Approach 435
5. Conclusions
This study investigated the optimization of EDM machining parameters on the MRR, EWR and
Cr.S.Dn in tungsten carbide (90WC-10Co) work pieces. A 3 mm diameter, EDM-3 grade graphite
electrode with dielectric oil Shell EDM Fluid 2A was used for machining. Experimental results showed
that:
• The maximum MRR was obtained at discharge current of 75 A, an off-time of 2 µs, and an
open-circuit voltage of 250 V.
• The minimum EWR, was obtained at a discharge current of 75 A, an off-time of 1600 µs, and
open-circuit voltage of 150 V.
• The minimum Cr.S.Dn, was obtained at a discharge current of 75 A, an off-time of 510 µs, and
open-circuit voltage of 150 V.
• The Taguchi method was used to significantly reduce the size of experiments. Confirmation
experiments verified the optimal EDM machining parameters obtained from the experimental
results.
Acknowledgement
The authors are grateful to the Thailand Research Fund, Office of the Higher Education Commission
and the National Research Council of Thailand for their funding support. The authors would like to
thank the National Metal and Materials Technology Centre (MTEC) for its kind support in supplying
materials and equipments for analysis.
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