Prediction of Material Removal Rate in Die-sinking Electrical Discharge Machining

Izwan, Nur Sheril Loke Binti; Feng, Zhujian; Patel, Jigar Bimal; Hung, Wayne

doi:10.1016/j.promfg.2016.08.054

Cited by 16 publications

(5 citation statements)

References 9 publications

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“…Lee et al, [10] presented a detailed overview of challenges in real-time measurement of electrode wear, dependency on shape of holes and tool materials while drilling (by EDM) high strength steel, cemented carbide and titanium alloys. A semi empirical model was proposed by Izwan et al, [11] to predict the MRR of Al 6061-T6, Domex 550 MC steel, HSLA steel and brass alloy using a rotary copper electrode. The MRR was dependent on cumulative electrical charge obtained from individual sparking cycle and the highest MRR was obtained at higher Ip and a longer Ton duration.…”

Section: Introductionmentioning

confidence: 99%

Optimisation of Current and Pulse Duration in Electric Discharge Drilling of D2 Steel Using Graphite Electrode

Deepak

Suhas

Ganti

et al. 2018

IJAME

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Electric discharge machining (EDM) is one of the viable techniques for machining of D2 steel, in which the material removal occurs by spark erosion. The poor selection of EDM parameters affect the machining quality and productivity. Considering this, the present work investigates the effect of current, charging and discharging time on the material removal rate (MRR) and the surface roughness (Ra) while machining of D2 steel using graphite electrode. The results were analysed using statistical methods to identify the effect of control parameters and to optimise the settings. The study shows that MRR and Ra was significantly influenced by current. At optimum settings, the MRR and the Ra obtained was 38.16 mg/min and 3.39 µm respectively. Morphological analysis of the machined surface show that the size of the globules formed decreased with increase in current.

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Section: Introductionmentioning

confidence: 99%

Optimisation of Current and Pulse Duration in Electric Discharge Drilling of D2 Steel Using Graphite Electrode

Deepak

Suhas

Ganti

et al. 2018

IJAME

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“…Conditions to be followed for these parameters are: the higher the better for MDR, the lower the better for EWR and the lower the better for SCD [ 38 ]. From the literature, it was observed that lower values of EWR and SCD can be obtained by lower current, pulse-on time, pulse-off time and temperature [ 39 ]. According to the design of experiments, it is not possible to select the desired parameter values so there is a requirement of optimization techniques for this problem.…”

Section: Resultsmentioning

confidence: 99%

Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating

et al. 2023

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One of the widely used non-traditional machines for machining of hard materials into complex shapes and different sizes is the electrical discharge machine (EDM). Recently, the EDM has been used for deposition by controlling the input parameters (current and duty cycle). This work was carried out to evaluate the readily available bronze (88% Cu + 12% Sn) electrode for deposition of copper material on titanium alloy. Experiments were conducted according to Taguchi experimental design considering the input parameters of current, Ton, Toff and preheating temperature of substrates. Titanium alloy was further hardened by preheating at temperatures of 100 °C, 300 °C and 500 °C and quenching in brine, castor oil and vegetable oil in order to avoid workpiece erosion. After this treatment, hardness, grain area, grain diameter and number of grains were characterized to compare with pretreated substrates. Then, the treated substrates were taken for copper deposition with the EDM. Output parameters such as material deposition rate (MDR), electrode wear rate (EWR), coating thickness (CT), elemental composition and surface crack density (SCD) were found. Material characterization was carried out using a scanning electron microscope (SEM) with energy dispersive X-ray spectroscopy (EDX) and optical microscopy. Output parameters were optimized with technique for order of preference by similarity to ideal solution (TOPSIS) to find optimum parameters. A sixth experiment with parameter values of Ton of 440 µs, Toff of 200 µs, preheating temperature of 300 °C and quenching medium of castor oil was optimum with MDR of 0.00506 g/m, EWR of 0.00462 g/m, CT of 40.2 µm and SCD 19.4 × 107 µm2.

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“…Two main EDM techniques may be distinguished, namely die-sinking EDM and wire cutting EDM. The die-sinking EDM uses an electrode to plunge into a workpiece and create a negative shape of the electrode, while the wire EDM utilizes a uniform wire that moves continuously and gradually cuts through a workpiece (Izwan et al, 2016). A schematic of the die-sinking EDM is shown in Figure 1.6.…”

Section: Electrical Discharge Machining Methodsmentioning

confidence: 99%

Remanufacturing and Advanced Machining Processes for New Materials and Components

Gevorkyan¹,

Rucki²,

Nerubatskyi³

et al. 2022

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Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint.The Open Access version of this book, available at www.taylorfrancis.com, has been made available under a Creative Commons Attribution-Non Commercial-No Derivatives 4.0 license.

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Prediction of Material Removal Rate in Die-sinking Electrical Discharge Machining

Cited by 16 publications

References 9 publications

Optimisation of Current and Pulse Duration in Electric Discharge Drilling of D2 Steel Using Graphite Electrode

Optimisation of Current and Pulse Duration in Electric Discharge Drilling of D2 Steel Using Graphite Electrode

Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating

Remanufacturing and Advanced Machining Processes for New Materials and Components

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