Optimization of Dry EDM Process Parameters Using Grey Relational Analysis

Pragadish, N.; Kumar, M. Pradeep

doi:10.1007/s13369-016-2130-6

Cited by 55 publications

(11 citation statements)

References 24 publications

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“…They found that thermal properties of the materials such as temperature behavior, thermal expansion coefficient, melting point and thermal conductivity influence performance measures greatly. Pragadish and Pradeep [16] have used modified tool for drilling holes using dry EDM process. They conducted experiments based on Taguchi methodology and used gray relational analysis (GRA) for optimizing multiple characteristics.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics

Singh

Patowari

Chandrasekaran

2020

J Braz. Soc. Mech. Sci. Eng.

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Drilling of micro-hole with fine edges and smooth internal surfaces finds numerous applications in manufacturing industries; holes drilled in injection nozzles, drug delivery orifices and spinneret holes are some of examples. This work carries out an experimental investigation and parametric optimization on micro-hole drilling using micro-electrical discharge machining (µ-EDM) process. The machining experiments are conducted employing Taguchi L16 orthogonal array for evaluating machining time (t) average overcut (AOV), taper angle (TA), entry overcut (EnOV), exit overcut (ExOV) and material removal rate (MRR) as process performances, while voltage (V), capacitance (pF) and feed rate (µm/s) are considered as process parameters. The influence of process parameters on the responses is studied at different cutting conditions. The drilled microholes profile is studied in terms of burrs, craters, spots on the edges and internal surfaces using micrographs obtained with optical and scanning electron microscopes. The ANOVA result reveals that capacitance is the most significant parameter for t, AOV, TA, MRR, EnOV and ExOV. For simultaneous optimization of three performance measures (i.e., t, AOV and TA), an overall evaluation criterion has been evaluated and optimum cutting conditions such as voltage: 80 V, capacitance: 100 pF and feed rate: 15 µm/s are obtained. The expected outcome obtained at the optimum condition is improved by 10.57% (36.934 to 40.839) over the grand average of performance. The confirmation experimental result at optimum cutting condition (i.e., 39.378) is comparable with the expected result (i.e., 40.839).

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Section: Introductionmentioning

confidence: 99%

Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics

Singh

Patowari

Chandrasekaran

2020

J Braz. Soc. Mech. Sci. Eng.

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“…∆ min and ∆ max are the minimum and maximum values of ∆, respectively. The next step is to obtain grey relational grade (GRG) by taking the average of grey relational coefficients using (12) [35,38].…”

Section: Optimization Using Grey Relational Analysismentioning

confidence: 99%

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

Ladeesh

Manu

2018

J Braz. Soc. Mech. Sci. Eng.

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Machining of advanced glass ceramics is of great importance and is a challenging task for the modern industries. In this study, a new hybrid technique of grinding-aided electrochemical discharge drilling (G-ECDD) is attempted which combines the grinding action of a rotating abrasive tool and thermal melting action of electrochemical discharges to perform drilling of borosilicate glass. G-ECDD is performed using a normal electrochemical discharge machine setup with a provision for using a rotating diamond-coated drill tool. The tool used is a hollow diamond core drill rather than the traditional solid abrasive tool. A spring-fed tool system was designed and developed to provide the tool-feed movement which will also help to maintain a balance between grinding action of diamond grits and thermal melting action of discharges. Preliminary experiments are conducted to identify the optimum spring force of the spring-fed system and tool rotational speed which can facilitate a balanced ECDM and grinding action for material removal. The effect of machining parameters like voltage, duty ratio, pulse cycle time and electrolyte concentration on material removal rate (MRR) and hole radial overcut (ROC) is investigated using response surface methodology (RSM). Duty ratio and voltage are found to be the most significant factors contributing MRR. Voltage and pulse cycle time are identified as the main factors controlling radial overcut of the drilled holes. Second-order regression models for MRR and ROC are developed using the data collected from the experiments using RSM. Grey relational analysis was used to optimize this multi-objective problem. A voltage of 90 V, duty ratio of 0.7, cycle time of 0.002 s and an electrolyte concentration of 3.5 M are found to be the best combination for optimizing the responses. Deterioration of bonding material and dislodging of diamond grits are found to be the major modes of tool wear during G-ECDD. The use of high-frequency pulsed DC increased the tool wear rate due to the less time available for heat dissipation between discharge cycles. Moreover, the wear at the end face of the tool will be accelerated due to the concentration of current density at edges during high-frequency operation. From the microscopic images of the machined surface, the material removal mechanisms involved in G-ECDD are found to be a combination of thermal melting by discharges, grinding action of diamond grits and high-temperature chemical etching effect of the electrolyte.

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“…There must always be a dielectric between the tool and the workpiece, which is a substance with a high electrical resistance. However, the dielectric does not have to be only in liquid form, but it can also be a gas [1,2]. The occurrence of an electric discharge between the tool electrode and the workpiece is caused by the supply of voltage from the machine generator, the discharge itself always occurring at the location of the strongest electric voltage field.…”

Section: Introductionmentioning

confidence: 99%

“…However, the dielectric does not have to be only in liquid form, but it can also be a gas. 1,2 The occurrence of an electric discharge between the tool electrode and the workpiece is caused by the supply of voltage from the machine generator, the discharge itself always occurring at the location of the strongest electric voltage field. The electric field thus sets in motion ions, which are constantly accelerating, forming an ionized conductive channel and creating a plasma zone with a temperature of 10,000 – 20,000 °C.…”

Section: Introductionmentioning

confidence: 99%

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

Mouralová

Polzer

Beneš

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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The unconventional technology of wire electrical discharge machining is a key engineering technology, designed primarily for machining of conventionally difficult machine materials. One of them is nickel alloys, which are majorly used in the aerospace and energy industries. The subject of research in this study was specifically the B1914 nickel-based superalloy, which was subjected to many analyses leading to an overall optimization of its machining using wire electrical discharge machining. In order to determine the effect of machine parameters setup (pulse off time, gap voltage, discharge current, pulse on time and wire feed) on cutting speed, topography, morphology, surface and subsurface layer quality, an extensive Box–Behnken design experiment consisting of 46 rounds was carried out. The analyses of the condition of the surface and subsurface layers were performed, including their chemical composition and changes caused by wire electrical discharge machining. It was found out that the factors like pulse off time, discharge current and pulse on time have the greatest effect on the cutting speed, although from the point of view of surface topography the parameter pulse off time is not significant. The remaining two parameters cause the cutting speed to act against the surface topography i.e. with the increasing cutting speed, the surface topography gets worse and vice versa.

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Optimization of Dry EDM Process Parameters Using Grey Relational Analysis

Cited by 55 publications

References 24 publications

Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics

Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

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