Investigation of magnetic field effect on MRR, EWR and surface roughness during EDM of AISI420 tool Steel

Electrical discharge machine (EDM) is a machining process that is not affected by the toughness or hardness of the sample material but the electrical and thermal conductivity. In EDM process, good surface quality can only be produced if low peak current is used but the machining process will take a long time causing material removal rate (MRR) to be too low. While the accumulated machine debris in the machining zone can cause abnormal discharge and disrupt the material removal process. The present research aims to study the magnetic field effect on MRR, EWR and SR for EDM process improvement. In addition to MRR, electrode wear rate (EWR) and surface roughness illustrate the effectiveness of the EDM process. The installation of magnetic devices in the EDM machining area were implemented and the experiments were conducted using graphite electrode and AISI420 as the workpiece. Permanent magnets having 0.54 Tesla were applied to produce magnetic fields during EDM operations. The presence of this magnetic field also contributes to the effectiveness of the flushing process because the evaporated debris will be attracted and attached to the magnet, then purify the spark gap medium for the next discharge process. Dielectric that stays clean and sparks under magnetic field influence increases the effectiveness of the material removal process. Surface roughness from Ra measurement has recorded 12.6% to 28.1% improvement when magnetic devices were applied on EDM. The spark ignition delays and the refinement of EDM spark enhanced the surface quality compared to conventional EDM. Comparison of images through optical microscopy and SEM also proves that the Magnetic Field Assisted EDM (MFAEDM) method is capable of producing better surface quality. This MFAEDM shows that action to hybridize EDM is necessary to increase EDM competency by attaining both of machining efficiency and high quality of surface integrity

Optimization of Coolant Technique Conditions for Machining A319 Aluminium Alloy Using Response Surface Method (RSM)

Background/Objectives: The paper discusses about the optimum cutting parameters with coolant techniques condition (1.0 mm nozzle orifice, wet and dry) to optimize surface roughness, temperature and tool wear in the machining process based on the selected setting parameters. The selected cutting parameters for this study were the cutting speed, feed rate, depth of cut and coolant techniques condition. Methods/Statistical Analysis Experiments were conducted and investigated based on Design of Experiment (DOE) with Response Surface Method. The research of the aggressive machining process on aluminum alloy (A319) for automotive applications is an effort to understand the machining concept, which widely used in a variety of manufacturing industries especially in the automotive industry. Findings: The results show that the dominant failure mode is the surface roughness, temperature and tool wear when using 1.0 mm nozzle orifice, increases during machining and also can be alternative minimize built up edge of the A319. The exploration for surface roughness, productivity and the optimization of cutting speed in the technical and commercial aspects of the manufacturing processes of A319 are discussed in automotive components industries for further work Applications/Improvements: The research result also beneficial in minimizing the costs incurred and improving productivity of manufacturing firms. According to the mathematical model and equations, generated by CCD based RSM, experiments were performed and cutting coolant condition technique using size nozzle can reduces tool wear, surface roughness and temperature was obtained. Results have been analyzed and optimization has been carried out for selecting cutting parameters, shows that the effectiveness and efficiency of the system can be identified and helps to solve potential problems

Effect of magnetic polarity on surface roughness during magnetic field assisted EDM of tool steel

Electrical discharge machining (EDM) is one of the non-traditional machining techniques where the process offers wide range of parameters manipulation and machining applications. However, surface roughness, material removal rate, electrode wear and operation costs were among the topmost issue within this technique. Alteration of magnetic device around machining area offers exciting output to be investigated and the effects of magnetic polarity on EDM remain unacquainted. The aim of this research is to investigate the effect of magnetic polarity on surface roughness during magnetic field assisted electrical discharge machining (MFAEDM) on tool steel material (AISI 420 mod.) using graphite electrode. A Magnet with a force of 18 Tesla was applied to the EDM process at selected parameters. The sparks under magnetic field assisted EDM produced better surface finish than the normal conventional EDM process. At the presence of high magnetic field, the spark produced was squeezed and discharge craters generated on the machined surface was tiny and shallow. Correct magnetic polarity combination of MFAEDM process is highly useful to attain a high efficiency machining and improved quality of surface finish to meet the demand of modern industrial applications

Plastic filling simulation comparison analysis of the gating system in injection moulding parameter

Purpose: The paper is discussed the anticipation of the simulation software precision with the real moulding process by setting up the distinctive metering stroke separation. Design/methodology/approach: The Inventor CAD software was used to design the product experiment and perform the simulation by applying MoldFlow application to produce the processing parameter defining for the injection moulding machines. Findings: The results predicted by this filling simulation appears reasonable result as compared to the injected product. Prediction analysis given by the software is exceptionally valuable for the injection moulding parameter setting machines which can diminish the time of mould setup and can reduce the trial stage on the production line. Research limitations/implications: The gating system is the most crucial part in injection moulding process and the limitation is to get the accurate filling time and injection pressure to ensure the cavity is fully filled before the material at the gate solidify. Originality/value: Gating system configurations are utilized to optimize the filling conditions of injection moulding parts. This important element was developed for achieving product quality. The utilize of simulation software is exceptionally supportive in the model designing stage to predict the quality and process capacity for the product. This paper presents the filling simulation of the side gate system to the injection moulding parameter

Optimization on the effect of nozzle orifice coolant supply during machining automotive material Al319

The thermal effect of the adhesive material of Aluminum Alloy 319 (Al319) on the cutting tool (insert) causes major problems in surface roughness, tool wear, as well as temperature due to the tendency to melt during the cutting process which can lead to the formation of formed edges, inaccuracies of measurement on the workpiece, surface damaged due to oxidation, which can reduce the life of the insert. The objective of this research is to optimize the nozzle cooling system method in the machining performance of Aluminum alloy 319 to achieve good surface roughness, low-temperature reading, and less insert wear by selecting machining parameters appropriate to cutting speed, cutting depth, and feed rate. The variety of orifice nozzle measurements used from nozzles 1.0 mm to 5.0 mm with the use of different machining parameters (cutting and spindle speed and with fixed cutting depth) using on CNC lathe condition. This method is done by the basic reaction surface (RSM), which is one of the alternative methods to minimize the cutting process that can be done at high cutting speed in which the temperature can minimize the formation of wear on the insert. Built-in edges and thermal construction can reduce the roughness of the work surface. The results of this research the smallest orifice nozzle used able to minimize the thermal impact and reduce the temperature that causes the arrangement of lower build edges (BUE). Therefore, better surface roughness, minimum insert use as well as low temperatures can be achieved. This is because the direction of the coolant can be directed at a point that can remove heat from the chips. The use of cutting fluid from the smallest nozzle size and technical conditions in the machining process can also be offered to obtain productivity, high-quality products, lower costs as well as minimize environmental impact (refrigerant waste is generated). This research is very useful to minimize the cost of the machining process budget and also increase productivity in the machining industry and can also decrease the dependency of machine operators on the skills and knowledge available

Optimisation of variation coolant system techniques in machining aluminium alloy Al319

Purpose Cutting parameters are often chosen for machining by machine operators in the industry. The experience and efficiency of the machine operator in producing a quality product are frequently used to decide parameter selection—low productivity results from improper parameter selection, inefficient machining, and technological issues. Today's key issues in the machining industry are focusing on increasing machining performance on surface roughness while minimising coolant usage. The study's objective is to enhance the performance of the nozzle lubrication system during the turning operation of an aluminium alloy 319 workpieces (Al319) to generate good surface roughness by applying turning parameters such as cutting speed, feed rate, and the depth of cut. Design/methodology/approach Response Surface Method (RSM) was used to create the experimental method for this investigation, carried out using a CNC lathe machine with two axial movements and a wet cooling nozzle with a size of 1.0 mm. Synthetic soluble lubricants, Al2O3-coated cemented carbide inserts, and Aluminium alloy 319 were utilised as cutting tools and workpiece materials. Findings To study the influence of cutting parameters on surface roughness, the Analysis of Variance (ANOVA) approach was utilised while the response surface method was performed to achieve an optimum machining performance (RSM). When comparing dry and wet cooling systems, the size of 1.0 mm nozzle shows appropriate surface roughness. According to the ANOVA analysis, the key factor impacting the surface roughness as machining performance in lubrication technique experiments was the utilisation of 1.0 mm nozzle size. Research limitations/implications The findings of combination machining parameters at a cutting speed of 270 m/min and a cutting depth of 0.60 mm at a feed rate of 0.08 mm/min offered the best results, achieving a surface roughness, Ra of 0.94 µm. Practical implications The use of coolant size nozzle 1.0 mm technology combined with the use of correct machining parameters can improve machining cuts. Originality/value The novel size of 1.0 mm nozzle in this current research is also valuable for reducing and increasing productivity in the machining business, as well as reducing dependency on machining operators' experience and abilities