Performance Analysis of Rapid Tool in Electrical Discharge Machining During Machining of Titanium Alloy (Ti6Al4V)

2018 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Performance Measures ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Machining Performance ◽  
Edm Electrodes ◽  
Titanium Alloy Ti6al4v ◽  
The Cost ◽  
Grey Relational ◽  
Conventional Machining

Titanium and its alloys are a class of metallic materials having high strength to weight ratio with excellent properties of resistance to temperature, corrosion and oxidation. These properties increase their use in aerospace, chemical and biomedical industries. Electrical discharge machining (EDM), a non-conventional machining process, is the most suitable process for the machining of titanium and its alloys. Generally, tool electrode for EDM application is prepared through various conventional and non-conventional machining processes. The cost of production of EDM electrodes accounts for more than 50% of the cost of the final product. Therefore, additive manufacturing (AM) technology can be suitably applied for direct manufacturing of the complex EDM electrodes. Selective laser sintering (SLS) is one of the appropriate AM processes for preparation of EDM tool electrode. In the present work, machining performance of the AlSi10Mg tool electrode produced through AM process along with copper and brass tool electrodes have been studied considering titanium alloy (Ti6Al4V) as work piece material and commercial grade EDM 30 oil as dielectric fluid. In addition to the tool electrodes, two more EDM parameters such as pulse-on-time (Ton) and discharge current (Ip) have been considered. Four performance measures like material removal rate (MRR), tool wear rate (TWR), average surface roughness (Ra) and surface crack density (SCD) are used to assess the machining performance. In order to reduce the number of experiments, design of experiment (DOE) approach like Taguchi’s L9 orthogonal array is used. Since the performance measures are conflicting in nature, grey relational analysis (GRA) is used to convert four performance measures into an equivalent single performance measure. The best parametric condition is reported for optimal grey relational grade.

Optimization of the Wire Electrical Discharge Machining Process Using Grey Relational Analysis and Taguchi Method

2015 ◽  
Vol 651-653 ◽  
pp. 738-743
Author(s):  
Oana Dodun ◽  
Vasile Merticaru ◽  
Laurenţiu Slatineanu ◽  
Margareta Coteaţă
Keyword(s):  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Wire Electrical Discharge Machining ◽  
Relational Analysis ◽  
The Wire ◽  
Grey Relational

The wire electrical discharge machining is a machining method able to allow detaching parts from plates type workpieces as a consequence of electrical discharges developed between workpiece and wire tool electrode found in a motion along its axis; there is also a work motion along the contour to be obtained. There are many factors able to exert influence on the sizes of parameters of technological interest. On the other hand, there are various methods that can be used in order to establish the optimal combination of the input factors, so that obtaining of machining best results is possible. When there are many process output factors, a problem of multiobjective optimization could be formulated. The Grey relational analysis method and the Taguchi method could be applied in order to optimize the wire electrical discharge machining process, when various criteria having distinct significances are considered. An experimental research was designed and developed in order to optimize the wire electrical discharge cutting of parts made of an alloyed steel, by considering six input factors: test piece thickness, pulse on time, pulse off time, wire axial tensile, current intensity and travelling wire electrode speed. As output parameters, one took into consideration surface roughness, wire tool electrode massic wear, cutting speed along the contour to be obtained. 16 experiments were developed in accordance with the requirements specific to a Taguchi table L16. The results of experiments were processed by means of Grey relational analysis method and Taguchi method.

scholarly journals Sub-Microstructure of Surface and Subsurface Layers after Electrical Discharge Machining Structural Materials in Water

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1040
Author(s):  
Sergey N. Grigoriev ◽  
Marina A. Volosova ◽  
Anna A. Okunkova ◽  
Sergey V. Fedorov ◽  
Khaled Hamdy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Structural Materials ◽  
12Kh18n10t Steel ◽  
Mean Deviation ◽  
Water Medium ◽  
Tool Electrode ◽  
Marquardt Algorithm ◽  
Subsurface Layers ◽  
Electrical Wear

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researched. The machining was conducted using a brass tool of 0.25 mm in diameter. The measured discharge gap is 45–60 µm for X10CrNiTi18-10 (12kH18N10T) steel and 105–120 µm for 2024 (D16) duralumin. Surface roughness parameters are arithmetic mean deviation (Ra) of 4.61 µm, 10-point height (Rz) of 28.73 µm, maximum peak-to-valley height (Rtm) of 29.50 µm, mean spacing between peaks (Sm) of 18.0 µm for steel; Ra of 5.41 µm, Rz of 35.29 µm, Rtm of 43.17 µm, Sm of 30.0 µm for duralumin. The recast layer with adsorbed components of the wire tool electrode and carbides was observed up to the depth of 4–6 µm for steel and 2.5–4 µm for duralumin. The Levenberg–Marquardt algorithm was used to mathematically interpolate the dependence of the interelectrode gap on the electrical resistance of the material. The observed microstructures provide grounding on the nature of electrical wear and nanomodification of the obtained surfaces.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

Effect of Arc Discharge Pressure on Discharge Current in EDM

2008 ◽  
Vol 381-382 ◽  
pp. 451-454
Author(s):  
Atsutoshi Hirao ◽  
S. Tai ◽  
H. Takezawa ◽  
Naotake Mohri ◽  
Kazuro Kageyama ◽  
...  
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Vibration Sensor ◽  
Work Piece ◽  
Tool Electrode ◽  
Discharge Pressure ◽  
Current Behavior

In electrical discharge machining (EDM), an electrical discharge occurs between a tool electrode and a work-piece, and removal of materials is carried out by vaporized explosion between the electrode and the work-piece. However, the mechanism of material removal in EDM is not well understood. In order to clarify this issue, the acoustic emission (AE) method has been applied to examine the force of explosion, and the Schlieren visualization method has been applied to observe the explosion. In this study, we investigate the effect of discharge current behavior on the occurrence of the AE waves by means of an optical fiber vibration sensor.

Study on the Strategies for Fabrication of Die Assembly with Typical Shaped Cavity by Using Electrical Discharge Machining

2012 ◽  
Vol 192 ◽  
pp. 118-122
Author(s):  
Ren Yu Feng ◽  
Min Wang ◽  
Zhi Jian Duan
Keyword(s):  
Service Life ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Thermal Characteristics ◽  
Suitable Method ◽  
Metallic Materials ◽  
Material Hardness ◽  
The Cost ◽  
Machining Strategies ◽  
Edm Process

Die assembly is a kind of special tools for fabrication of metal or non-metallic materials parts with required design and purpose. Generally, the high material hardness for die assembly should be selected to increase the service life and reduce the cost in manufactory industry. Electrical discharge machining (EDM) is a suitable method for fabrication of die assembly as the material remove in EDM process mainly depends on the material's thermal characteristics, regardless of the hardness. In this paper, the machining strategies for fabrication of die assembly with typical shaped cavity using EDM were discussed, according to the different cavity structures, the best machining strategies were proposed

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

2019 ◽  
Vol 969 ◽  
pp. 644-649
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Work Piece ◽  
Tool Electrode ◽  
Affecting Factors ◽  
Inconel 718 Alloy ◽  
Electrical Discharge Drilling ◽  
Pulse On Time

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

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