Finite Element Modeling of Discharge Zone in Micro-EDM Process

2012 ◽  
Author(s):  
Jose Mathew ◽  
Deepak G. Dilip ◽  
Mathew J. Joseph ◽  
Basil Kuriachen
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Removal Rate ◽  
Discharge Zone ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Uniform Mesh ◽  
Tool Electrode ◽  
Micro Edm ◽  
Edm Process

Micro-EDM (μ-EDM) is a derived form of EDM process especially evolved to perform micro-machining. The μ-EDM process is based on the thermoelectric energy created between a work piece and an electrode submerged in a dielectric fluid. When the work piece and the electrode are separated by a specific small gap, a pulsed discharge occurs which removes material from the work piece through melting and evaporation. A thermo-electrical approach to model the temperature variation in the discharge gap using finite element method has been done so as to predict the temperature distribution in the discharge channel and find out the maximum temperatures acting on the work piece as well as the tool electrode and the subsequent material removal rate on the work piece. The temperature generated on the surface of the work piece depends upon the various properties of the conductor; as a result it varies depending on the conductor. An axi-symmetric two-dimensional model was used for modeling the region between the two electrodes. Tungsten and titanium alloy were the materials used for cathode and anode, respectively. A 60μm by 60μm region was taken for modeling the process. An uniform mesh of equal dimensions was made to carry out the modeling. The finite element results were compared with the results obtained by conducting experiments on titanium alloy using single spark generator device under the same discharge conditions that were given as input for the mathematical model. The MRR obtained agrees very well with the predicted MRR thus validating the model.

Optimization of Surface Roughness Parameters by Different Multi-Response Optimization Techniques During Electro-Discharge Machining of Titanium Alloy

2019 ◽  
pp. 82-108 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Discharge Current ◽  
Desirability Function ◽  
Optimization Techniques ◽  
Work Piece ◽  
Tool Electrode ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Edm Process

In this chapter, the EDM process is performed by taking titanium alloy as work piece and AlSiMg prepared by selective laser sintering (SLS) process as tool electrode along with copper and graphite. The EDM is performed by varying different process parameters like voltage (V), discharge current (Ip), duty cycle (τ), and pulse-on-time (Ton). The surface roughness parameters like Ra, Rt, and Rz are measured by the use of surface roughness measurement machine. To reduce the number of experiments, design of experiment (DOE) approach like Taguchi's L27 orthogonal array has been used. The surface properties of the EDM specimen are optimized by desirability function approach, TOPSIS and VIKOR method, and the best parametric setting is reported for the EDM process. All the optimization techniques convergence to the same optimal parametric setting. The type of tool is the most significant parameter followed by discharge current and voltage. Better surface finish of EDM specimen is produced with lower level of parametric setting along with the use of AlSiMg RP electrode during EDM.

scholarly journals Comparative Analysis of Dry-EDM and Conventional EDM in machining of Hastelloy

2021 ◽  
Vol 12 (3) ◽  
pp. 3538-3543
Author(s):  
Apurva A Kulkarni Et.al
Keyword(s):  
High Velocity ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Dielectric Medium ◽  
Work Piece ◽  
Tool Electrode ◽  
Dry Edm ◽  
Discharge Gap ◽  
Edm Process

Dry EDM may be a modification of the traditional electrical discharge machining (EDM) process during which the liquid dielectric is replaced by a gaseous medium. High velocity gas is supplied through it into the discharge gap. The flow of high velocity gas into the gap facilitates removal of debris and prevents excessive heating of the tool and work piece at the discharge spots. it's now known that aside from being an environment–friendly process, other advantages of the dry EDM process are low tool wear, lower discharge gap, lower residual stresses, smaller white layer and smaller heat affected zone.[1] Keeping literature review into consideration, during this research, an effort has been made by selecting compressed gas as a dielectric medium, with Hastelloy as a work piece material and copper as a tool electrode. Conventional experiments were also performed. Experiments are performed using Taguchi DoE orthogonal array to watch and analysis the consequences of various process parameters to optimize the response variables like material removal rate (MRR) and gear wear rate (TWR).

Powder Mixed Micro Electro Discharge Milling of Titanium Alloy: Investigation of Material Removal Rate

2011 ◽  
Vol 383-390 ◽  
pp. 1759-1763 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Nur Atiqah Binti Abdul Rahman ◽  
Erniyati Binti Mohamad Aris
Keyword(s):  
Titanium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Optimum Level ◽  
Machining Parameters ◽  
Micro Edm ◽  
Discharge Energy ◽  
Powder Concentration

This paper presents effects of silicon carbide (SiC) powder in dielectric fluid of micro EDM on material removal rate (MRR). The aim is to identify the optimum level of SiC powder concentration and other micro EDM parameter for higher MRR. The work material was titanium alloy (Ti-6Al-4V) machined with tungsten carbide (WC) electrode by varying two machining parameters SiC powder concentrations and discharge energy. By using two factor four level factorial design of experiment, sixteen experiments were conducted. Data were analyzed by Design Expert® software. In this experimental investigation, maximum MRR of 7.3 µg/min was obtained for 24.75 g/l SiC powder concentration and 56.77 µJ discharge energy. The analysis of variance revealed that the SiC powder concentration in dielectric fluid on micro EDM has significant influence on MRR Ti-6Al-4V titanium alloy.

Performance Evaluation of Dry EDMed Aluminium Alloy

2015 ◽  
Author(s):  
M. Pradeep Kumar ◽  
N. Pragadish
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Removal Rate ◽  
Research Work ◽  
Work Piece ◽  
Tool Electrode ◽  
Dry Edm ◽  
Input Parameters ◽  
Pulse On Time ◽  
Edm Process

In this research work, experiments were conducted using Electrical Discharge Machining (EDM) in dry and conventional mode, and the results were compared and analyzed. LM13 Aluminium alloy is used as the workpiece and pure cylindrical copper rod is used as the tool electrode. Since the machining was difficult in dry EDM, some modifications were made in the existing tool design to conduct the experiments in dry EDM. The experiments were designed using Taguchi’s L27 orthogonal array. Discharge current (I), gap voltage (V), pulse on time (TON), pressure (P) and speed (N) were chosen as the various input parameters. Three levels of values were chosen for each input parameter, whereas speed was chosen as the fixed parameter. The variation in the material removal rate (MRR), surface roughness (SR), surface morphology and elemental composition of the machined surface due to variation in the input parameters were analyzed in both dry and conventional mode. Better MRR, and surface roughness were observed in the work piece machined under conventional EDM process. The MRR is observed to be 84% more in the conventional mode when compared with dry EDM. Also, when compared to the dry EDM, about 15.33% better SR values is observed in the conventional EDM process.

Analysis of Micro-EDM Process of D3 Die-Steel Employing NaNO3 Mixed Deionised Water-An Optimal Approach

2019 ◽  
Vol 11 (4) ◽  
pp. 50-66
Author(s):  
Golam Kibria ◽  
Ishwer Shivakoti ◽  
B.B. Pradhan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Qualitative Assessment ◽  
Gray Relational Analysis ◽  
Dielectric Fluid ◽  
Micro Edm ◽  
Die Steel ◽  
Edm Process

In micro-electrical discharge machining, the selection of proper dielectric fluid is one of the important issues regarding the machining rate, geometrical accuracy, as well as surface profiles obtained. Each type of dielectric fluid has their own values of viscosity, flash point, cooling rate and compositions. In addition, depending on the resistivity and other characteristics, dielectric fluid has its own value of dielectric strength. In the present article, an attempt has been made to carryout experimentation during micro-EDM process of D3 die-steel employing NaNO3 salt mixed deionised water. Taguchi-GRA (gray relational analysis) based experimental scheme and optimization technique has been applied to analyze the process parameters to optimize the material removal rate, tool wear rate, overcut and taper of micro-hole generated. Optical microscopic images were also analysed for qualitative assessment of process parameters.

Finite element modeling of material removal rate in micro-EDM process with and without ultrasonic vibration

2020 ◽  
Vol 10 (3) ◽  
pp. 311-319
Author(s):  
Mayank Choubey ◽  
K.P. Maity ◽  
Abhishek Sharma
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Micro Edm ◽  
Two Dimensional ◽  
Content Type ◽  
Element Modeling ◽  
Edm Process

PurposeThis research explores the finite element modeling of the crater and material removal rate (MRR) in micro-electrical discharge machining (micro-EDM) with and without vibration of the workpiece. The application of workpiece vibration in the micro-EDM process improved flushing efficiency and enhanced material removal rate (MRR).Design/methodology/approachIn this work, the two-dimensional axisymmetric finite element method (FEM) has been developed to predict the shape of the crater with and without vibration. The temperature distribution on the workpiece surface with and without vibration has been obtained in the form of the contour plot.FindingsThe MRR obtained from the numerical model revealed that there was an enhancement in MRR in micro-EDM with vibration as compared to without vibration. The effect of process parameters on MRR in micro-EDM with and without is also presented in this work.Originality/valueIn this work, the two-dimensional axisymmetric FEM model has been developed to predict the shape of the crater with and without vibration.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Electrical Discharge Coating by Copper-Tungsten Composite Electrode Prepared by Powder Metallurgy Route

2018 ◽  
pp. 195-224 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Harmony Search ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Weight Percentage ◽  
Material Deposition ◽  
Edm Process ◽  
Powder Metallurgy Route

Electrical discharge machining (EDM), a thermo-mechanical machining process, is used in producing complicated intrinsic cavity in difficult-to- machine materials with excellent surface finish. One of the major disadvantage of EDM process is the tool wear, which can be used advantageously for coating purpose. Coating is a unique method of EDM process by the use of electrode prepared via powder metallurgy route. Copper and tungsten powders in weight percentage of 30 and 70 respectively are used for the preparation of the tool electrode by varying the PM process parameters like compaction pressure and sintering temperature. The substrate on which coating is made is chosen as AISI 1040 stainless steel with EDM oil as the dielectric fluid. During coating, influence of parameters like discharge current, duty cycle and pulse-on-time on material deposition rate, tool wear rate and radial under deposition are studied. To find out the best parametric combination Grey Relational Analysis method combined with Harmony Search algorithm has been employed.

Fabrication of Tapered Micro Pillars on Titanium Using Electric Discharge Micromachining

2014 ◽  
Author(s):  
V. K. Jain ◽  
Vishnu Suthar ◽  
Anjali V. Kulkarni
Keyword(s):  
Titanium Alloy ◽  
Removal Rate ◽  
Statistical Technique ◽  
Surgical Instruments ◽  
Work Piece ◽  
Chemical Plants ◽  
Electrically Conductive ◽  
Taper Angle ◽  
Micro Pillars ◽  
Pulse On Time

Materials are made harder, tougher, heat resistant and more corrosion resistant which make them difficult-to-machine by traditional machining methods. Titanium and its alloys are in the group of these difficult-to-machine materials, and these alloys have applications in aerospace, power generation, surgical instruments, automobile, chemical plants etc. Ti-6Al-4V is amongst the commonly used titanium alloy, and the current research is focused on its efficient machining. Electro discharge micromachining can be used for producing features in micro range on electrically conductive materials. Straight micro electrodes have been produced using EDMM process. The main objective of the current research is to achieve array of tapered micro pillars on Ti-6Al-4V Work piece material using EDMM process. The effect of process parameters such as gap voltage, discharge current, pulse on-time and duty cycle on the response parameters such as taper angle, material removal rate (MRR) and tool wear rate (TWR) are studied. The experiments are designed using statistical technique. After studying the results of the experiments, the array of micro tapered pillars of different taper angles is produced to see the feasibility of fabrication of tapered pillars on titanium alloy using EDMM process.

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