Evaluation of Micro-EDM Milling Performance Using Pulse Discrimination

2014 ◽  
Author(s):  
F. Modica ◽  
G. Guadagno ◽  
V. Marrocco ◽  
I. Fassi
Keyword(s):  
Tool Wear ◽  
Process Parameters ◽  
Pulse Width ◽  
Removal Rate ◽  
Micro Edm ◽  
Erosion Process ◽  
Machining Performance ◽  
Short Pulses ◽  
Milling Performance ◽  
Micro Channels

In this paper, the pulse discrimination of gap voltage and discharge current waveforms occurring during micro-EDM milling of micro-channels is analyzed in relation to process parameters variation and machining performance. The pulse classification algorithm discriminates voltage and current waveforms into four defined pulse types: short, arc, delayed and normal. The micro-channels are manufactured in hardened steel using an energy level corresponding to the finishing regime and varying pulse width, frequency, gain and gap. The analysis shows that when the erosion process is stable, normal discharges are predominant. Delayed and short pulses are very sporadic. A major number of arcs can be detected when the gap is decreased and gain increased, i.e. erosion speed and feed rate are increased and affect in particular tool wear. Also the increase of the pulse width has an effect on tool wear, though the percentage of the arcs remains small. On the contrary, material removal rate does not seem to be apparently related to the percentage of arcs as the process parameters are varied, since these values are spread in a constant range for all parameter combinations. The evaluation of the depth errors does not provide any significant insights about the erosion process in relation to the considered process parameters.

scholarly journals An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6074
Author(s):  
Tingting Ni ◽  
Qingyu Liu ◽  
Zhiheng Chen ◽  
Dongsheng Jiang ◽  
Shufeng Sun
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Deionized Water ◽  
Micro Edm ◽  
Nano Particle ◽  
Machining Performance ◽  
Machined Surface ◽  
Micro Electrical Discharge Machining ◽  
Lower Tool

Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM

2013 ◽  
Vol 675 ◽  
pp. 365-369 ◽  
Author(s):  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Hai Ping Tsui ◽  
Yuan Feng Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Dielectric Fluids ◽  
Edm Process

The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

Multi-Objective Optimization of Microturning Process Parameters Using Particle Swarm Technique

2013 ◽  
Author(s):  
Nithin Tom Mathew ◽  
Kanthababu Mani
Keyword(s):  
Tool Wear ◽  
Process Parameters ◽  
Removal Rate ◽  
Computational Cost ◽  
Particle Swarm ◽  
Depth Of Cut ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Confirmation Test ◽  
First Time

In this work, for the first time an attempt has been made to carry out multi-objective optimization for tool based microturning process parameters using particle swarm optimization (PSO) technique. The input microturning process parameters considered are speed, feed and depth of cut. The output parameters considered are material removal rate (MRR), surface roughness (Ra) and tool wear (TW). The significant parameters are identified individually using ANOVA and main effect plots. However, it is observed that the main goal of the manufacturers is to produce high quality products in shorter interval of time. In order to meet the above objective, multi-objective optimization is carried out to achieve simultaneously higher MRR, low Ra and low TW using PSO. From the PSO analysis, it is observed that the combination of microturning parameters such as speed (18.25 m/min), feed (9.31 μm/rev) and depth of cut (14.61 μm) results in high MRR, low Ra and low tool wear. The PSO analysis indicates that it is a promising optimization algorithm due to its simplicity, low computational cost and good performance. A confirmation test was carried out to validate the predicted results.

OPTIMIZATION OF TURNING PARAMETERS FOR SURFACE INTEGRITY PROPERTIES ON INCOLOY 800H SUPERALLOY USING CRYOGENICALLY TREATED MULTI-LAYER CVD COATED TOOL

2019 ◽  
Vol 26 (02) ◽  
pp. 1850139 ◽  
Author(s):  
A. PALANISAMY ◽  
T. SELVARAJ
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
Dry Sliding Wear ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Performance ◽  
Incoloy 800H

In this work, an attempt has been made to optimize the process parameters on turning operation of INCOLOY 800H, with the aid of cryogenically treated (24[Formula: see text]h, 12[Formula: see text]h and untreated) multi-layer chemical vapor deposition (CVD) coated tools. The influencing factors like cutting speed, feed rate, depth of cut and cryogenic treatment were selected as input parameters. Surface roughness, microhardness and material removal rate (MRR) were considered as output responses. The experimentation was planned and conducted based on Taguchi L27 standard orthogonal array (OA) with three levels and four factors. Multi-criteria decision making (MCDM) methods like grey relational analysis (GRA) and technique for order preference by similarity to ideal solution (TOPSIS) have been used to optimize the turning parameters in this work. Similar results were obtained from these MCDM techniques. Analysis of variance (ANOVA) was employed to identify the significance of the process parameters on the responses. Experimental research proved that machining performance could be improved efficiently at cutting speed is 55[Formula: see text]m/min, feed rate is 0.06[Formula: see text]mm/rev, depth of cut is 1[Formula: see text]mm and 24[Formula: see text]h cryogenically treated tool. Tool wear was analyzed for the cutting tool machined at the optimum cutting condition with the help of scanning electron microscope (SEM) and energy dispersion spectroscopy (EDS). Dry sliding wear test was also conducted for the optimal condition. The percentage improvement in machining performances is 12.70%.

scholarly journals Parametric optimization of Edm on Hastelloy C-276 Using Taguchi L18 Technique

2018 ◽  
Vol 7 (2.7) ◽  
pp. 714 ◽  
Author(s):  
SK Khadar Basha ◽  
Murahari Kolli ◽  
M V.Jagannadha Raju
Keyword(s):  
Process Parameters ◽  
Discharge Current ◽  
Removal Rate ◽  
Extreme Environments ◽  
Industrial Applications ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Current Electrode ◽  
Pulse On Time ◽  
Pulse Off Time

Due to development in machining science the use of composites and alloys is a great deal for every industry. Hastelloy C276 the most versatile corrosion resistant nickel based super alloy which is used for industrial applications is considered for doing the            experiments .The high nickel and molybdenum content provides better corrosion resistance at extreme environments. In this report, the experiments are performed by using Taguchi L18 technique and their results are used for performance of each process parameters on their output responses. The process parameters considered for experimentation are discharge current, pulse- on- time, type of electrode and pulse off time for the output responses of material removal rate and surface roughness. Eco-friendly (drinking water) is used as a dielectric fluid. The experiments are designed and conducted using Taguchi L18 technique and analyze the influence of each process parameters on machining performance characteristics. Further, mathematical equations were developed using the statistical software MINITAB17.0.ANOVA is used for analyzing the experimental results obtained. It was observed from the response table that the average values of MRR and SR for pulse on time, discharge current, electrode are identified as important process parameters.  

scholarly journals Effects of Process Parameters on Material Removal in Vibration-Assisted Polishing of Micro-Optic Mold

Micromachines ◽  
2018 ◽  
Vol 9 (7) ◽  
pp. 349 ◽  
Author(s):  
Jiang Guo ◽  
Hirofumi Suzuki
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Removal Efficiency ◽  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Grain Sizes ◽  
Tool Influence Function ◽  
Polishing Pressure ◽  
Lower Material

Process parameter conditions such as vibrating motion, abrasives, pressure and tool wear play an important role in vibration-assisted polishing of micro-optic molds as they strongly affect material removal efficiency and stability. This paper presents an analytical and experimental investigation on the effects of process parameters, aimed at clarifying interrelations between material removal and process parameters which affect polishing quantitatively. The material removal rate (MRR) and surface roughness which represent the polishing characteristics were examined under different vibrating motions, grain sizes of abrasives and polishing pressure. The effects of pressure and tool wear conditions on tool influence function were analyzed. The results showed that 2D vibrating motion generated better surface roughness with higher material removal efficiency while a smaller grain size of abrasives created better surface roughness but lower material removal efficiency. MRR gradually decreases with the increase of polishing pressure when it exceeds 345 kPa, and it was greatly affected by the wear of polisher when wear diameter on the polisher’s head exceeds 300 μm.

scholarly journals Fabrication of µ-Channels on Pure-Ti using USM and Optimization of Process Parameters

2019 ◽  
Vol 8 (2) ◽  
pp. 6508-6515
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Three Dimensional ◽  
Machining Performance ◽  
Machining Processes ◽  
Optimization Of Process Parameters ◽  
Micro Channels ◽  
Type Power ◽  
Micro Tools ◽  
Abrasive Size

Today, the appropriate use of precision machining to produce three dimensional miniaturized structures or micro devices is another challenging task. Thus, presently miniaturization has emerged as a thrust area of research. The micro components are normally provided with micro channels which are created by using micro tools with the help of nonconventional machining processes. The aim of this paper is to examine machining performance of making micro channels in pure-Ti using ultrasonic machining. The effect of abrasive type, power rating, slurry concentration, feed rate and abrasive size has been investigated on responses namely metal removal rate (MRR) and surface roughness (SR). Taguchi based L18 (mixed level) orthogonal array is selected for the planning of experiments. Finally, the validation experiments have been performed at suggested optimal settings for result reproducibility.

A Study of Material Removal Process in Abrasive Waterjet Milling

2011 ◽  
Vol 325 ◽  
pp. 621-626 ◽  
Author(s):  
Keivan Dadkhahipour ◽  
Jun Wang
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Removal Process ◽  
Milling Performance ◽  
Amorphous Glass ◽  
Cutting Zone ◽  
Selection Of

An experimental investigation of the material removal process in abrasive waterjet (AWJ) milling is presented. The experiment was conducted on an amorphous glass for milling channels of controlled depth. It is found that the channels are formed through four different zones, i.e. an opening zone, a steady-cutting zone, a unsteady-cutting zone and a finishing zone. The effect of process parameters on the channel formation process and the major milling performance measures (depth of cut and material removal rate) is then discussed. It is found that AWJ milling is a viable process for machining applications and the milling performance can be reasonably controlled through the selection of process parameters.

Optimization of Machining Parameters Using EDM in Gas Media Based on Taguchi Method

2012 ◽  
Vol 459 ◽  
pp. 170-175 ◽  
Author(s):  
Der An Wang ◽  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Shih Feng Fan ◽  
A Cheng Wang
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Pressure Peak ◽  
Machining Parameter ◽  
Machining Characteristics

The aim of this study is to investigate the machining characteristics of gas media used in electrical discharge machining (EDM). The process parameters were designed based on Taguchi method to manage the experimental work. The main process parameters such as machining polarity, gas pressure, peak current, pulse duration, type of gas media, and servo reference voltage were adopted to explore their effects on machining performance in terms of material removal rate (MRR) and surface roughness (SR) for SKD 61 tool steel. The experimental observed values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters affecting obviously the machining performance were determined by analysis of variance (ANOVA). The optimal combination level of machining parameter for each machining characteristic was obtained by the S/N ratio analysis according to Taguchi methodology.

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