Enhancement Material Removal Rate Optimization of Sinker EDM Process Parameters Using a Rectangular Graphite Electrode

This article discusses the optimization of sinker electrical discharge machining (sinker EDM) processes using SPHC material that has been hardened. The sinker EDM method is widely employed, for example, in the production of moulds, dies, and automotive and aeronautical components. There is neither contact nor a cutting force between the electrode and the   work material in sinker EDM. The disadvantage of the sinker EDM is its low material removal rate. This work aims to optimize the material removal rate (MRR) using graphene electrodes in a rectangular configuration. The SPHC material was selected to determine the optimum MRR model of the sinker EDM input parameter. The Taguchi experimental design was chosen. The Taguchi technique used three input parameters and three experimental levels. Pulse current (I), spark on time (Ton), and gap voltage were among the input parameters (Vg). The graphite rectangle was chosen as an electrode material. The input parameter effect was evaluated by S/N ratio analysis. The result showed that pulse current has the most significant impact on material removal rate in the initial study, followed by spark on time and gap voltage. All input parameters are directly proportional to the MRR. For optimal material removal rate, the third level of pulse current, spark on time, and gap voltage must be maintained. In addition, the proposed Taguchi optimization model could be applied to an existing workshop floor as a simple and practical electronic tool for predicting wear and future research

Investigation of surface integrity, material removal rate and wire wear ratio for WEDM of Nimonic 80A alloy using GRA and Taguchi method

AbstractThis paper presents the investigation on surface integrity, material removal rate and wire wear ratio of Nimonic 80A using WEDM process. Taguchi's design of experiments methodology has been used for planning and designing the experiments. All of the input parameters and two factors interactions have been found to be statically significant for their effects on the response of interest. SEM was performed on the machined samples to investigate the effect and microstructure of the samples after machining. A higher pulse-on time setting leads to thicker recast layer. At lower value of pulse-on time and higher value of pulse-off time, the wire deposition on the machined surface is low

Enhancement material removal rate optimization of sinker EDM process parameters using a rectangular graphite electrode

This article discusses the optimization of sinker electrical discharge machining (sinker EDM) processes using SPHC material that has been hardened. The sinker EDM method is widely employed, for example, in the production of moulds, dies, and automotive and aeronautical components. There is neither contact nor a cutting force between the electrode and the work material in sinker EDM. The disadvantage of the sinker EDM is its low material removal rate. This work aims to optimize the material removal rate (MRR) using graphene electrodes in a rectangular configuration. The SPHC material was selected to determine the optimum MRR model of the sinker EDM input parameter. The Taguchi experimental design was chosen. The Taguchi technique used three input parameters and three experimental levels. Pulse current (I), spark on time (Ton), and gap voltage were among the input parameters (Vg). The graphite rectangle was chosen as an electrode material. The input parameter effect was evaluated by S/N ratio analysis. The result showed that pulse current has the most significant impact on material removal rate in the initial study, followed by spark on time and gap voltage. All input parameters are directly proportional to the MRR. For optimal material removal rate, the third level of pulse current, spark on time, and gap voltage must be maintained. In addition, the proposed Taguchi optimization model could be applied to an existing workshop floor as a simple and practical electronic tool for predicting wear and future research

Experimental Investigation on Surface Roughness in Electrical Discharge Turning of Ti-6Al-4V Alloy

This study presents a novel EDM turning process specially designed and developed to generate precise cylindrical forms on hard and difficult-to-machine materials. For this purpose, a specially designed turning spindle is used. The spindle was mounted on a conventional die-sinking EDM machine to rotate the workpiece. Axially symmetric parts can be manufactured by feeding the shaped tool into the rotating workpiece. In this way an axisymmetric workpiece can be made with small tools at both macro and micro levels. Effects of machining parameters, such as the current, pulse-on time, rotational speed, flushing pressure, and duty factor, on the surface roughness of Ti-6Al-4V alloy in electrical discharge turning were investigated. Taguchi\u27s design of experiment technique was used. Analysis of variance and regression analysis were performed on experimental data. The signal-to-noise ratio analysis was employed to find the optimal condition

TAGUCHI OPTIMIZATION OF MULTIPLE PERFORMANCE CHARACTERISTICS IN THE ELECTRICAL DISCHARGE MACHINING OF THE TIGR2

Electrical discharge machining (EDM) provides many advantages for the shaping of metallic materials. It also provides better surface quality for Ti alloys used in the defense industry.  In this study, experiments were carried out with different EDM parameters using the Titanium (Gr2) alloy. A number of novel industrial processes have been developed as a result of advances in technology. For a product to be developed, these novel approaches must be utilized to determine optimum parameters. The Taguchi method was applied in the experiments with EDM. The impact the test parameters had on the performance characteristics of tool wear rate, material removal rate, depth, and surface roughness were analyzed by the variance analysis (ANOVA). Quadratic regression analyses were carried out to reveal the correlation between the experimental results and the predicted values. According to the ANOVA results for material removal rate (MRR), tool wear rate (TWR), depth, and surface roughness, the most effective factor was amperage, at 99.66%, 99.56%, 87.95%, and 81.12%, respectively.  The best value for average surface roughness was determined to be 3.29 µm obtained at 120 μs time-on, 8 A, and 40 μs time-off.Electrical discharge machining (EDM) provides many advantages for the shaping of metallic materials. It also provides better surface quality for Ti alloys used in the defense industry.  In this study, experiments were carried out with different EDM parameters using the Titanium (Gr2) alloy. A number of novel industrial processes have been developed as a result of advances in technology. For a product to be developed, these novel approaches must be utilized to determine optimum parameters. The Taguchi method was applied in the experiments with EDM. The impact the test parameters had on the performance characteristics of tool wear rate, material removal rate, depth, and surface roughness were analyzed by the variance analysis (ANOVA). Quadratic regression analyses were carried out to reveal the correlation between the experimental results and the predicted values. According to the ANOVA results for material removal rate (MRR), tool wear rate (TWR), depth, and surface roughness, the most effective factor was amperage, at 99.66%, 99.56%, 87.95%, and 81.12%, respectively.  The best value for average surface roughness was determined to be 3.29 µm obtained at 120 μs time-on, 8 A, and 40 μs time-off

Analysis of control factors and surface integrity during wire-EDM of Inconel 718 alloy using T-GRA approach

In today’s competitive modern manufacturing sectors, there is a vital need of utter precision and rigorous processing using various manufacturing approaches that directly influences the cost and processing duration of mechanized materials in addition to the consistency of the finished products. Therefore, it’s essential to figure out the required output by adjusting the control factors of any machining techniques which resulted in optimal values of the desired outcome. In this study, machining evaluation and process optimization is carried out on volumetric extraction of material namely material removal rate (MRR), kerf obtained during the machining (KW) and surface roughness (SR) of Inconel 718 superalloy during CNC controlled wire- electrical discharge machining. Four controllable factors- pulse interval, wire speed, pulse duration and peak current are considered to investigate the influence on performance measures. Taguchi's L16 has been used to construct the set of experiments before physical experimental runs and most influencing factors have been evaluated using ANOVA. SEM images and EDXS analysis have been resorted to examine the morphology of Inconel 718. These findings assist in identifying the topography of the machined surface. Further, the optimum integration has been obtained for the best yield and recorded using grey relational analysis integrated with Taguchi’s technique (T-GRA). The unfamiliarity of the work is based on consideration of zinc coated thin wire electrode and Taguchi-Grey combined approach of modelling with four levels of experimental design

Analysis of the Influence of Different EDM Parameters Using Taguchi Technique

Electrical discharge machining (EDM) is a non-traditional material removal process developed in late 1940s has now become the most important technology in manufacturing industries. Taguchi technique has been applied for design of experiments with three input factors and their trinity levels utilizing L9 orthogonal array. The nine specimens were machined with different electrodes material where AISI 304 stainless steel had been used as a workpiece with kerosene as dielectric fluid. The major aim of this study is the evaluation to choice the principle specifications of electrical discharge machining with the assist of Taguchi technique and utilizing Minitab program in condition of material removal rate and electrode wear rate. The variance conditions examined during production the research on electrical discharge machining would be the electrodes material, current and workpiece thickness. The effect of each parameters and excellent performance variables will be achieve by means of ANOVA examination and conformed by investigation to enhance method

A multivariate quality loss function approach for parametric optimization of non-traditional machining processes

Due to various added advantages over the conventional material removal processes, non-traditional machining (NTM) processes have now been widely applied in different manufacturing industries. To achieve the desired response values, it is always recommended to operate these NTM processes at their optimal parametric settings. Various single response optimization techniques are already available to determine the optimal combinations of NTM process parameters for achieving maximum or minimum value of a single response. In this paper, a multivariate quality loss function approach is adopted for simultaneous optimization of responses for three NTM processes. It is observed that this approach outperforms the other multi-response optimization techniques, like desirability function, distance function and mean squared error methods with respect to the achieved re-sponse values. With modification of the corresponding objective function and constraints of the de-veloped non-linear programming problem, it can be effectively applied to any non-traditional as well as conventional machining process as a multi-objective optimization tool

Investigations on Machining Aspects of Inconel 718 During Wire Electro-Discharge Machining (WEDM): Experimental and Numerical Analysis

Wire electro- discharge machining (WEDM) is known as unique cutting in manufacturing industries, especially in the good tolerance with intricate shape geometry in die industry. In this study the workpiece has been chosen as Inconel 718. Inconel 718 super alloy is widely used in aerospace industries. This nickel based super alloy has excellent resistance to high temperature, mechanical and chemical degradations with toughness and work hardening characteristics materials. Due to these properties, the machinability studies of this material have been carried-out in this study. The machining of Inconel 718 using variation of wire electrode material (brass wire electrode and zinc coated brass wire) with diameter equal to 0.20mm has been carried out. The objective of this study is mainly to investigate the various WEDM process parameters and performance of wire electrodes materials on Inconel 718 with various types of cutting. The optimal process parameter setting for each of wire electrode material has been obtained for multi-objective response. The kerf width, Material Removal Rate (MRR) and surface finish, corner error, corner deviation and angular error are the responses which are function of process variables viz. pulse-on time, discharge current, wire speed, flushing pressure and taper angle. The non-linear regression analysis has been developed for relationship between the process parameter and process characteristics. The optimal parameters setting have been carried out using multi-objective nature-inspired meta-heuristic optimization algorithm such as Whale Optimization Algorithm (WOA) and Gray Wolf Optimizer (GWO). Lastly numerical model analysis has been carried out to determine MRR and residual stress using ANSYS software and MRR model validated with the experimental results. The overlapping approach has been adopted for solving the multi-spark problem and validate with the experimental results

Effect of chromium (cr) particle size and span-20 surfactant on Aisi d2 hardened steel using electrical discharge machining

Existing manufacturing industries are facing challenges from modern advanced materials such as composite, super alloys, and hardened steels, which are hard and difficult to machine and process. Since it is not suitable to use conventional machining of the hard material, non-conventional machining such as electrical discharge machining (EDM) is one of the ideal techniques in dealing with these materials. However, the limitations of EDM will cause lower productivity and poor surface quality. Therefore, Powder Mixed Electrical Discharge Machining (PMEDM) has emerged as one of the advanced and innovative technique to eliminate the some of the disadvantages of EDM method. The fine powder particles are added into the tank then the spark gap is filled up with these additives particles. These electrically conductive powder particles reduce the insulating strength of dielectric fluid and increase the spark gap distance between tool electrode and workpiece, which due to this EDM process becomes more stable, thereby improving the EDM efficiency and quality of the machined surface. This research emphasizes the machining of AISI D2 hardened steel with EDM through adding both of micro and nano chromium powder mixed and span-20 surfactant using copper tool electrode. Then, machining productivity (i.e material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra) and surface characteristics were investigated in terms of surface morphology, surface topography, recast layer thickness (RL) and microhardness. It was indicated that the addition of micro-nano chromium powder and span-20 surfactant to the dielectric notably enhanced the machining efficiency and better surface quality. The highest improvement 35~46 % of MRR, 29~69 % of Ra and 42~54 % of RL were attained at combination of micro-nano chromium powder and span-20 surfactant, respectively. There is no significant effect on EWR. For this purpose, full factorial 32 design of experiments (DOE) was chosen which consists of three levels of PMEDM parameters of chromium powder concentrations (Cp) and Span- 20 surfactant concentrations (Cs) for both micro and nano chromium powder. Response Surface Methodology (RSM) was utilized for responses optimization and Central Composite Design (CCD) was applied in designing the experiments to evaluate the effects of PMEDM parameters to three responses, MRR, EWR and Ra. Thus, this is clarify that the potential of addition of Cr powder and span-20 surfactant into dielectric fluid ability to gives a notable potential to be utilized as one of innovative technique, improving efficiency and better surface quality