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.
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
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.
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.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
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
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.
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.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
Electrical discharge machining is a nonconventional machining process which enables machining of complex and intricate shapes, hard materials that are precise and difficult to machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The process involves spark erosion in the presence of dielectric fluid. In this work SCM 420low alloy steel is the material used for the machining purpose with electrolyte copper as tool. This work investigates effect of process parameters peak current (IP), Pulse on time (Ton) and gap voltage (Vg) on Material removal rate (MRR) and surface roughness (Ra). Response surface methodology is used for experimental design. The suggested model can be used in the different manufacturing firms by selecting right combination of process parameters to achieve optimal values of output responses.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
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.
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.
Anaysis of Material Removal Rate of AISI 304 SS In EDM Processijsrd.com
EDM has become an important and cost-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 AISI 304 Stainless steel 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 current, pulse on time and duty cycle. Taguchi method is applied to create an L27 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), Surface Roughness (SR) and Overcut (OC) is studied and investigated. The tool material is copper. The results obtained showed that current was the most significant parameter followed by pulse on time and the least significant was the duty cycle for the entire three responses namely Material removal rate, Surface roughness and overcut. With the increase in current and duty cycle MRR increased but for pulse on time it increased only up to 100 µs and then started to decrease. SR increased significantly with the increase in current; for pulse on time it increased up to 100 µs and after that there was no significant increase; and in case of duty cycle SR increased up to 70% and then started to decrease. OC increased with the increase in current and pulse on time but in different fashion and in case of duty cycle, OC increased up to 70% and then started decreasing.
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
Electrical Discharge Machining (EDM) is a non
conventional machining process which can be used to
machine electrically conductive work piece. The
electric discharge machine provides an effective
solution for machining hard conductive materials and
reproducing complex shapes. EDM involves the
phenomena such as: spark initiation, dielectric
breakdown, and thermo-mechanical erosion of metals.
High cost of non conventional machine tools,
compared to conventional machining, Optimization is
one of the techniques used in manufacturing process
area to arrive for the best manufacturing conditions,
which is an essential need for industries towards
manufacturing of quality products at lower cost. In
this paper various optimization technique such as
Taguchi method, artificial neural network (ANN),
Genetic Algorithms (GA), grey relational analysis
(GRA), Response Surface Methodology (RSM) used
in the field of electric discharge machining process.
The main objectives of optimization are to (i)
maximize the material removal rate (MRR), (ii)
minimize the surface roughness value and (iii)
maximize the tool wear ratio.
Investigation And Optimization Of EDM Process Of AISI 4140 Alloy Steel Using ...IJERA Editor
The purpose of this research work is to determine the optimized settings of key machining factors like pulse on
time, discharge current and duty cycle for AISI 4140 alloy steel using various tool electrodes. The output
responses will be measured are material removal rate (MRR),surface roughness(SR) and tool wear rate(TWR).
Mathematical models are proposed for the above are L27 orthogonal array. The micro structural changes in the
work piece after machining process will also be examined by the use of SEM.
Использование шаблонов и RTTI для конфигурации симулятора флеш-накопителя - Г...Yandex
Флеш-накопители используются в самых разных устройствах, от мобильных телефонов до компьютеров и серверов. Для каждой модели накопителя нужна прошивка с определённым набором параметров, которые могут отличаться в зависимости от ситуации. В докладе будет описан универсальный фреймфорк на С++, который предоставляет разработчикам симуляторов простой, прозрачный и быстрый доступ к любому параметру. Тестировщикам же он позволяет управлять конфигурациями при помощи стандартных инструментов редактирования и слияния.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
Electrical discharge machining is a nonconventional machining process which enables machining of complex and intricate shapes, hard materials that are precise and difficult to machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The process involves spark erosion in the presence of dielectric fluid. In this work SCM 420low alloy steel is the material used for the machining purpose with electrolyte copper as tool. This work investigates effect of process parameters peak current (IP), Pulse on time (Ton) and gap voltage (Vg) on Material removal rate (MRR) and surface roughness (Ra). Response surface methodology is used for experimental design. The suggested model can be used in the different manufacturing firms by selecting right combination of process parameters to achieve optimal values of output responses.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
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.
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.
Anaysis of Material Removal Rate of AISI 304 SS In EDM Processijsrd.com
EDM has become an important and cost-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 AISI 304 Stainless steel 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 current, pulse on time and duty cycle. Taguchi method is applied to create an L27 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), Surface Roughness (SR) and Overcut (OC) is studied and investigated. The tool material is copper. The results obtained showed that current was the most significant parameter followed by pulse on time and the least significant was the duty cycle for the entire three responses namely Material removal rate, Surface roughness and overcut. With the increase in current and duty cycle MRR increased but for pulse on time it increased only up to 100 µs and then started to decrease. SR increased significantly with the increase in current; for pulse on time it increased up to 100 µs and after that there was no significant increase; and in case of duty cycle SR increased up to 70% and then started to decrease. OC increased with the increase in current and pulse on time but in different fashion and in case of duty cycle, OC increased up to 70% and then started decreasing.
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
Electrical Discharge Machining (EDM) is a non
conventional machining process which can be used to
machine electrically conductive work piece. The
electric discharge machine provides an effective
solution for machining hard conductive materials and
reproducing complex shapes. EDM involves the
phenomena such as: spark initiation, dielectric
breakdown, and thermo-mechanical erosion of metals.
High cost of non conventional machine tools,
compared to conventional machining, Optimization is
one of the techniques used in manufacturing process
area to arrive for the best manufacturing conditions,
which is an essential need for industries towards
manufacturing of quality products at lower cost. In
this paper various optimization technique such as
Taguchi method, artificial neural network (ANN),
Genetic Algorithms (GA), grey relational analysis
(GRA), Response Surface Methodology (RSM) used
in the field of electric discharge machining process.
The main objectives of optimization are to (i)
maximize the material removal rate (MRR), (ii)
minimize the surface roughness value and (iii)
maximize the tool wear ratio.
Investigation And Optimization Of EDM Process Of AISI 4140 Alloy Steel Using ...IJERA Editor
The purpose of this research work is to determine the optimized settings of key machining factors like pulse on
time, discharge current and duty cycle for AISI 4140 alloy steel using various tool electrodes. The output
responses will be measured are material removal rate (MRR),surface roughness(SR) and tool wear rate(TWR).
Mathematical models are proposed for the above are L27 orthogonal array. The micro structural changes in the
work piece after machining process will also be examined by the use of SEM.
Использование шаблонов и RTTI для конфигурации симулятора флеш-накопителя - Г...Yandex
Флеш-накопители используются в самых разных устройствах, от мобильных телефонов до компьютеров и серверов. Для каждой модели накопителя нужна прошивка с определённым набором параметров, которые могут отличаться в зависимости от ситуации. В докладе будет описан универсальный фреймфорк на С++, который предоставляет разработчикам симуляторов простой, прозрачный и быстрый доступ к любому параметру. Тестировщикам же он позволяет управлять конфигурациями при помощи стандартных инструментов редактирования и слияния.
Power Quality Enhancement in Wind Connected Grid System Interface Based On St...IJERA Editor
Wind energy has become one of the significant alternative renewable energy resources because of its abundance
and the strong drive for its commercialization. Dynamic electric load variations and wind velocity excursions
cause excessive changes in the prime mover kinetic energy and the corresponding electrical power injected into
the AC grid utility system. In this paper, a scheme based on the low cost static switched filter compensator
(SSFC) is presented for voltage sag/swell compensation, power factor improvement in distribution grid
networks with the dispersed wind energy interface. The SSFC scheme is based on an intermittent switching
process between two shunt capacitor banks to be one of them in parallel with the capacitor of a tuned arm filter.
Two regulators based on a tri- loop dynamic error driven inter-coupled weighted modified proportional-integralderivative
(PID) controller which is used to modulate the PWM.
The Static Switched Filter Compensation (SSFC) compensation scheme which enhances the system
power quality has been fully validated using MATLAB–Simulink. The effectiveness of this compensation
scheme approach is demonstrated using a study case of 3 bus system. Simulation results show that there is
improvement in harmonics reduction, voltage sag/swell compensation, power factor improvement at generator
bus, load bus, and infinite bus respectively
Determination of Immobilization Process Parameters of Corynebacterium glutami...IJERA Editor
The parameters of the immobilized process of Corynebacterium glutamicum on kappa carrageenan were identified by
Plackett-Burman matrix, and the experiments were designed by response surface methodology having the central
composite designs (RSM-CCD). The maximum yield of cell immobilization on kappa carrageenan carrier reached at
78% ± 2%. Optimal parameters were 3 grams kappa carrageenan per 100 militters sterile water and 58.58 million
cfu/mL, forming gels at 100C for 25 minutes and the speed when soaking particles of 150 rpm for 120 minutes in 0.58
M potassium chlorua solvent. The immobile finished products are applied in L-lysine production, their reusing ability
is 3 times and the total yield of L-lysine was accumulated 93 g/L in medium during 96 fermented hours. The L-lysine
productivity of the batch fermentation was 0.969 g.L-1
.h-1
. And the set-up storage conditions are the mixed solvent of
CaCl2 0.5% (w/v) and KCl 0.5% (w/v); pH is 7.0 in 40C. After 60 storage days, the survival cell rate was remained
51%.
Autonomy CYMHSU Collaborative Castlegar BC Dec 2014tkettner
Obstacles in moving through the developmental stage of autonomy vs shame can lead to teen narcissism and defiance. The anger displayed by teens can best be understood by having empathy for the underlying core emotion of shame. Parenting, teaching, and health care counselling strategies are offered to help a young person mature into a resilient, healthy and autonomous individual.
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
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
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.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
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 materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
effect of electrode material and geometry on edm performance for ohns dies s...INFOGAIN PUBLICATION
Modern EDM machinery is capable of machining micro-hole, thin slots, geometrically complex or hard material components, that are precise and difficult to machine, such as heat treated tool steels, composites, super alloys, etc. The studies of an experimental investigation evaluate the effects of EDM machining parameters such as MRR, EWR and Surface Roughness with two different electrode materials. The process parameters such as Input current, Pulse on time and duty cycle keeping flushing pressure constant. The full factorial design of experiment (L25) is used to study the effects of machining parameters. Investigations indicate that the output parameters of EDM increases with the increase in input current and the best machining rates are achieved with copper with through hole electrodes, better surface roughness compare to brass electrode. A brass electrode with higher input current and maximum pulse on time resulted in more EWR compared to copper electrodes. Also the increase in MRR by copper electrode, it improves the SR during Electric Discharge Machining.
Effect Of Wire Edm Process Parameters On Surface Roughness Of Aisi-4140 (Carb...dbpublications
WEDM is used for cutting intricate or complicated shapes which are not possible with conventional machining methods. Wire cut EDM is a cutting process used widely where conventional machining processes are not useful. A metal wire with a Dielectric medium travels through a path and perform machining procedure .The main objective of the present work is to investigate the effects of various WEDM process parameters on the machining quality and to obtain the optimal sets of process parameters like Pulse-ON time, Pulse-OFF time, current, wire feed are studied by conducting an experiment. Taguchi Method is to design the experiment. L16 orthogonal array is used to conduct the experiment. An AISI-4140 (carbon steel) is used as a work piece material in the form of square bar. The surface roughness (SR) is selected as response variable.
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.
Comparison of fuzzy logic and neural network for modelling surface roughness ...ijmech
Surface roughness is the main indicator of technological performances of a component for electrical discharge machining (EDM). EDM process of manganese alloyed cold-work tool steel was modelled. In this paper we used the fuzzy logic (FL) and neural network (NN) to predict the effect of machining variables (discharge current and pulse duration) on the surface roughness of manganese alloyed cold-work tool steel in order to improve and increase its range of application. The experiments are carried out on
manganese alloyed cold-work tool steel, processed with electrodes made of copper. The values of surface
roughness predicted by these models are then compared. All models show good agreement with experimental results. When compared to the NN and FL models, the NN model has shown a significant forecast improvement. The results indicate that the NN model is an effective algorithm to forecast the surface roughness in EDM.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
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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.
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 34 (=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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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
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An Electrode Shape Configuration on the Performance of Die Sinking Electric Discharge Machine (EDM): A Review
1. Abhijeetsinh V Makwana Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 11(Version - 5), November 2014, pp.117-122
www.ijera.com 1 | P a g e
An Electrode Shape Configuration on the Performance of Die
Sinking Electric Discharge Machine (EDM): A Review
Abhijeetsinh V Makwana1, Kapil S Banker2
PG Scholar1, Assistant Professor2
1,2Department of Mechanical Engineering, Shankersinh Vaghela Bapu Institute of Technology, GTU
Ahmedabad, Gujarat - India
Abstract—
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.
Keywords: EDM, Electrode Shape Configuration, Taguchi Method, DOE, Parameter analysis.
I. INTRODUCTION TO DIE-SINKING
EDM
In EDM, a potential difference is applied
between the tool and work piece. Both the tool and
the work material are to be conductors of electricity.
The tool and the work material are immersed in a
dielectric medium. A gap is maintained between the
tool and the work piece. Depending upon the applied
potential difference and the gap between the tool and
work piece, an electric field would be established. If
the work function or the bonding energy of the
electrons is less, electrons would be emitted from the
tool (assuming it to be connected to the negative
terminal). Such emission of electrons are called or
termed as cold emission. The “cold emitted” electrons
are then accelerated towards the job through the
dielectric medium. As they gain velocity and energy,
and start moving towards the job, there would be
collisions between the electrons and dielectric
molecules. Such collision may result in ionization of
the dielectric molecule depending upon the work
function or ionization energy of the dielectric
molecule and the energy of the electron. This cyclic
process would increase the concentration of electrons
and ions in the dielectric medium between the tool
and the job at the spark gap. The concentration would
be so high that the matter existing in that channel
could be characterized as “plasma”. The high speed
electrons then impinge on the job and ions on the
tool. The kinetic energy of the electrons and ions on
impact with the surface of the job and tool
respectively would be converted into thermal energy
or heat flux. Such intense localized heat flux leads to
extreme instantaneous confined rise in temperature
which would be in excess of 10,000 C such localized
extreme rises in temperature leads to material
removal. Material removal occurs due to instant
vaporization of the material as well as due to melting.
Thus to summarize, the material removal in EDM
mainly occurs due to formation of shock waves as the
plasma channel collapse owing to discontinuation of
applied potential difference
Fig.1 Sparkonix EDM Setup
II. LITERATURE REVIEW
In this paper few selected research paper related
to Die-sinker EDM.The studies carried out in these
papers are mainly concerned with the different
electrode shape configuration and EDM input
parameters such as current, voltage, pulse on time,
duty cycle, etc. and how these affect the machining
RESEARCH ARTICLE OPEN ACCESS
2. Abhijeetsinh V Makwana Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 11(Version - 5), November 2014, pp.117-122
www.ijera.com 2 | P a g e
characteristics like MRR, SR, TWR, Micro structure etc. Mr. Dr. A.K.Sarathe et al. [1] has studied that the influence of process parameters and electrode shape configuration on the machining characteristics such as surface quality, material removal rate and electrode wear. In this review he observe that for high MRR main process parameters are peak current, pulse on time ,pulse off time, whereas for electrode wear are mainly influenced by peak current and pulse on time. Surface quality is mainly influenced by peak current. He found thatthe main effects of process parameters such as peak current, pulse on-time, pulse off-time, higher-order effect of pulse on-time, and the interaction effect of discharge current and pulse on- time have significantcontributions in MRR. The MRR increases linearly, whereas the TWR increases nonlinearly with discharge current. He also found that the influence of the shape of electrodes on surface roughness is found to be insignificant.However, a round shape electrode produces a smoother surface followed by thesquare, triangular andthediamond shaped electrodes. Also For round shaped electrodes MRR was the maximum and undergoes less wear followed by the square, triangular and the diamond shaped electrodes. It is because of no vulnerable sharp corner at the sparking tip. Chandramouli S et al. conducted [2] investigating EDM process parameters by using the Taguchi method and select the optimum result from that. The effect of various process parameters on machining performance is investigated by the Taguchi method. They use the input parameters as current, pulse time on, and pulse time off and the other side of Material removal rate (MRR), Tool wear rate (TWR), and surface roughness (SR). The taguchi method is used to formulate the experimental layout, ANOVA method is used to analysis the effect of input parameters on machining characteristics and find the optimum process parameters.
D. C. Chen et al. [3] having the purpose of to find process parameters with the help of Taguchi method. The process parameters are used as current, pulse time on, duty cycle, the machining duration. In this paper they use several of method for finding the optimum parameters of EDM. The work piece material A6061-T6 aluminum alloy is used. They use the Taguchi and ANOVA method for finding Optimum result with the help of the Minitab software. The experimental investigations have considered four fundamental EDM parameters, namely the pulse current (PC), the pulse-on duration (ON), the duty cycle (DC), and the machining duration (MD). The optimum set of parameter areas, pulse time (1.5 A), pulse on duration (50 μs), duty cycle (20) and machining duration (500 ms). The surface roughness of the machined specimen determined primarily by the values assigned to the pulse current and duty cycle. The optimum parameter setting established for material process also in low surface roughness when applied to the machining of CuZn40 brass alloy specimens, and thus the general applicability of the Taguchi design solution is confirmed. Bhola Jha, K.Ram and Mohan Rao [4] conducted an overview of technology and research in electrode designand manufacturing in sinking electrical discharge machining.He suggested number of ways to improve electrode design and devised various ways of manufacturing and reports a review on the research relating to EDM electrode design and its manufacturing for improving and optimizing performance measures and reducing time and cost of manufacturing. He finally concluded that Design and manufacturing of electrode play an important role in EDM technology. Rajesh Choudhary et al. [5] conducted investigations on the machining of EN-3 1 die steel with different electrode materials (copper, brass and graphite) with electrical discharge machining (EDM) process. This study presents the analysis and evaluation of heat affected zones (HAZ) of the workpiece surfaces machined using different tool electrodes by EDM. The kerosene oil of commercial grade has been used as dielectric fluid. From the micro-structural analysis study it has been observed that heat affected zone is much deeper in the specimen machined by graphite electrode as compared to other tool electrodes. The following conclusions were arrived at: I) For the EN-3 I work material. Copper electrodes have high MRR as compared to the machining performed by graphite and brass electrodes. ii) Among the three tested electrode materials, brass electrodes produce comparatively high surface finish for the tested work material at high values of discharge current, while graphite shows the poor surface finish. Vishal J Nadpara et al. performed [6] on AISI D3 tool steel using graphite electrode of 10 mm diameter. The process parameters are taken on the basis of Taguchi Method. The objective of the paper is to optimize the process parameters of machining in high. Medium and low wear factors through duty cycle. In this paper they use the input process parameters as current, duty cycle and pulse time ON and the opposite side the output process parameters as MRR and EWR. In this they also used as taguchi method for getting the optimum result of selecting the best process parameters.
3. Abhijeetsinh V Makwana Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 11(Version - 5), November 2014, pp.117-122
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Fig.2 working principle of EDM [6]
B.S. Reddy et al. [7] carried out a study on the effect
EDM parameters over MRR, TWR, SR and hardness.
Mixed factorial design of experiments and multiple
regression analysis techniques had been employed to
achieve the desired results. The parameters in the
decreasing order of importance for; MRR: servo,
duty cycle, current and voltage; TWR: current, servo
and duty cycle; SR: current.
Nilesh M. Vohra optimizing [8] of various
parameters which are affected on different types of
machining characteristics of EDM. The objective of
this paper is to investigate the optimum cutting
parameters for a work piece of SS 304 & tool
material use as copper, aluminum and brass
combination on fuzzy logic control based EDM. This
experiment was accomplished by Taguchi Method. In
this paper they use process parameters are Current,
spark gap voltage, Ton, and Toff. And at the other
side of output they use MRR, TWR, and SR. In the
paper they conclude that the Gap voltage has highest
effect on MRR.
Fig.3 Experimental setup [8]
S. P. Nipanikar et al. optimizing [9] of process
parameters of EDM by the taguchi method. In this
they used work piece material as AISI D3 steel
material. The Taguchi method is used to formulate
the experimental layout, to analyze effect of each
parameter on the machining characteristics, and to
predict the optimal choice for each EDM parameters
such as current, gap voltage, and duty cycle and pulse
time on. They use output parameters as MRR and
EWR and Radial overcut. The Martial Removal Rate
is mainly affected by peak current, and least affected
by duty cycle. The EWR is mainly affected by peak
current and least influenced by gap voltage. The peak
current has maximum effect on radial over cut, and
least affected by gap voltage.
M. S. Sohani & V. N. Gaitonde & B.
Siddeswarappa &A. S. Deshpande [10] studied
Investigations into the effect of tool shapes with size
factor consideration in sink electrical discharge
machining (EDM) process. He presents paper with
the application of response surface methodology
(RSM) for investigating the effect of tool shapes such
as triangular, square, rectangular, and circular with
size factor consideration along with other process
parameters like discharge current, pulse on-time,
pulse off-time, and tool area. Also The RSM-based
mathematical models of material removal rate (MRR)
and tool wear rate (TWR) have been developed using
the data obtained through central composite design.
He finally concluded that the best tool shape for
higher MRR and lower TWR is circular, followed by
Triangular, rectangular, and square cross sections.
From the parametric analysis, it is also observed that
the interaction effect of discharge current and pulse
on-time is highly significant on MRR and TWR,
whereas the main factors such as pulse off-time and
tool area are statistically significant on MRR and
TWR.
Fig.4 Photograph of tools andworkpieces used [10]
4. Abhijeetsinh V Makwana Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 11(Version - 5), November 2014, pp.117-122
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Ahsan Ali Khan, Mohammad Yeakub Ali and Md. Mohafizul Haque [11] conducted a review of Study of Electrode Shape Configuration on the Performance of Die Sinking EDM. He concluded the performance of die sinking EDM due to the shape configuration of the electrode. In addition of the above conclusion he also concluded that the effect of electrode shape on material removal rate (MRR), electrode wear rate (EWR), wear ratio (WR), and average surface roughness (Ra) has been investigated for mild steel work material and copper electrode. The shapes of the electrodes were round, square, triangular, and diamond of constant cross-sectional area of 64 mm2. Experiments were repeated for three current values of 2.5, 3.5, and 6.5 A. finally Electrodes of four different shapes of constant cross-sectional area were used for experiment with different discharge current. The MRR, EWR, WR, and surface roughness were measured and analyzed.
Round Square
Triangular Diamond Fig.5 Selected shape configurations of electrode for die sinking EDM. [11] The effects of the machining parameters (MRR, TWR and SR) in EDM on the machining characteristics of SKH 57 high-speed steel were investigated by Yan- Cherng et.al [12]. Experimental design was used to reduce the total number of experiments. Parts of the experiment were conducted with the L18 orthogonal array based on the Taguchi method. Moreover, the signal-to-noise ratios associated with the observed values in the experiments were determined by ANOVA and F - test. The relationship of MRR and SR with pulse duration graph in different peak current is obtained. During the experiment MRR increases with peak current MRR initially increased to a peak at around 100 μs, and then fell.
Fig.6 MRR and surface roughness with pulse duration graph[12] Yusuf Keskin et al [13] conducted an experimental study for determination of the effects of machining parameters on surface roughness in electrical discharge machining (EDM). In this the data obtained for performance measures have been analyzed using the design of experiments methods and a considerably profound equation is obtained for the surface roughness using power, pulse time, and spark time Parameters. He finally concluded that Effects of machining parameters on the surface roughness values of machined components by EDM have beeninvestigated experimentally. It is apparent that the surface roughness has anIncreasing trend with an increase in the dischargeduration. This is mainly due to more discharge energy released during this time and expanding the discharge channel. P. Narender Singh et al. [14] discuss the evolution of effect of the EDM current (C), Pulse ON-time (P)and flushing pressure (F) on MRR, TWR, taper (T), ROC, and surface roughness (SR) on machining as-cast Al-MMC with 10% SiCp . And use of metal matrix composites. ELEKTRAPULS spark erosion machine was used for the purpose and jet flushing of the dielectric fluid, kerosene, was employed. Brass tool of diameter 2.7mm was chosen to drill the specimens. An L27 OA, for the three machining parameters at three levels each, was opted to conduct the experiments. ANOVA was performed and the optimal levels for maximizing the responses were established. Scanning electron microscope (SEM) analysis was done to study the surface characteristics. Puertas et al. [15] carried out results which showed that the intensity and pulse time factor were the most important in case of SR while the duty cycle factor was not significant at all. The intensity factor was again influential in case of TWR. The important factors in case of MRR were the intensity followed by duty cycle and the pulse time.
5. Abhijeetsinh V Makwana Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 11(Version - 5), November 2014, pp.117-122
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III. CONCLUSION
From all the above detailed literature review and analysis ofvarious process parameters of EDM process, the following points have been observed.
The main effects of process parameters such as discharge current, pulse on time, pulse off time, higher-order effect of pulse on time, and the interaction effect of discharge current and pulse on time have significant contribution in MRR.
The best tool shape for higher MRR and lower TWR is circular, followed by Triangular, rectangular, and square cross sections.
The MRR increases linearly with discharge current. And the MRR increases with pulse on- time duration and then starts decreasing with increase in pulse on time duration.
The influence of the shape of electrodes on surface roughness is found to be insignificant. However, a round shape electrode produces a smoother surface followed by the square, triangular and the diamond shaped electrodes.
Cavities made by EDM die sinking may have intricate shapes and it is difficult to achieve high accuracy at the sharp corner of the cavities. The single irregular electrode contains several geometries such as flat, round, square surface, pointed tip, etc. which removes materials with different effectiveness. The present paper proposes to carefully select the EDM parameters for machining cavities with multiple and intricate shaped electrodes.
It has also been found that the copper having high material removal rate with respect to some other material like as aluminum, gun metal, brass, etc. REFERENCES
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