Analysis of Energy Distribution in Sinker EDM Process

GRD Journals- Global Research and Development Journal for Engineering | Volume 1 | Issue 12 | November 2016
ISSN: 2455-5703
Analysis of Energy Distribution in Sinker EDM

Process
Kumari Nilu
Department of Mechanical Engineering
Saroj Institute of Technology and Management, Lucknow- 226021, U.P (India)
Mr. Abhishek Singh
Saroj Institute of Technology and Management, Lucknow226021, U.P (India)
Mr. Amit Kumar Singh

Saroj Institute of Technology and Management, Lucknow226021, U.P (India)
Abstract
Electro Discharge Machining (EDM) is used for machining electrically conducting /semi conducting, tough and brittle material
.This process is best suited for making intricate cavities and contour, dies, section of complex geometry, moulds. The work piece
material selected for this study is mild steel and tool is copper electrode. Dielectric flow rate, discharge current, pulse on time,
pulse off time is considered as input parameters. In the present work ANOVA analysis is used to study the significance of
process variable on Material Removal Rate (MRR) and Tool Wear Rate (TWR) by using simple conduction equations, we can
calculate the energy transferred to each for material removal rate and tool wear rate. Also energy transferred to work piece, tool
and dielectric fluid can be calculated by using conduction equation, convection equation, energy carried away by debris, and the
best suited input parameters can be found for the maximum energy transfer to work piece. After than energy responsible for tool
wear were calculated and the optimum parameter are found in order to minimize the tool wear The energy distribution in the
electrical discharge machining (EDM) process is most important phenomenon for study the variation of fraction of input
discharge energy with the help of thermo-mathematical models during EDM of mild steel by varying the machining parameter
current and pulse duration.
Keywords- EDM, Conduction, Convection, MRR, TWR
I. INTRODUCTION
Electric discharge machining is nonconventional manufacturing process uses spark for material removal.EDM is used for deep
cutting, for sharp inside corner complicated shape, mould making tool and die industries, machining of geometrically complex,
hard material with accuracy, nonconventional machining process uses sound, light, electrical and chemical form of energy .High
accuracy surface finish can be obtain with non-conventional machine where electrical form of energy is used. One of the main
advantages of EDM is a consequence of the thermal process. It is based on Eroding material by melting and evaporation, so the
hardness of the work piece is no limitation for machining. Even the hardest steel grades can be machined with almost same
machining speed as for softer steels.
Drilling, milling, grinding and other conventional machining operations are replaced by electric discharge machining.
Tool or electrode, work piece dielectric liquid are used for extremely tough and brittle electrically conductive materials in the
process of making moulds, dies, section of complex geometry and intricate shapes desired shape is obtained by using spark
process is not making actual contact between tool and work piece .The electric spark produces huge amount of heat melting
work piece but it must be controlled carefully .The increase in temperature during working of EDM is up to 800-1200. No
direct contact between electrode and work piece so no stress is produced. EDM process is used in aerospace automobile and
electronic industry to making prototype and production parts of difficult material .For fulfilling this requirement EDM machine
has been developed. in the field of medical and surgical instrument, sports aerospace, automobile and electronic industries
including automobile and electronic industries automotive R & D areas EDM is used. Super alloys, high-tech ceramics heat
resistant steels can be easily machined with EDM.
II. LITERATURE REVIEW

H. Singh et al. (2012) study that energy distribution in the Electrical Discharge Machining (EDM) process influences the
material removal rate, and other machining characteristics like crater geometry, relative wear ratio and surface roughness. During
this process the electrical energy is converted into heat energy and this energy is distributed among the electrode, work piece and
the dielectric fluid. The fraction of the energy which is transferred to the work piece is the useful energy and this energy should
be maximum, for optimum utilization of energy. This fraction of energy is one of the important parameters used in the existing
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Analysis of Energy Distribution in Sinker EDM Process

(GRDJE/ Volume 1 / Issue 12 / 020)
thermo-physical models of EDM process. Due to apparent incongruities and conflicting data early researchers conjectured the
same value of fraction of energy transferred to electrodes for all machining parameters in their models for numerically
calculating the volume and geometry of the crater formed. This assumption is one of the reasons of error in the models from the
experimental data. So this study is planned to experimentally study the variation of this fraction of input discharge energy with
the help of thermo-mathematical models during EDM of Tungsten-Carbide by varying the machining parameters current and
pulse duration. The data calculated in this study can be further used in the existing thermos physical models, expecting to bring
the models preciously more close to the real conditions. This data will also be helpful for numerically calculating the optimum
parameters using optimum value of the fraction of energy transferred to the electrodes especially work piece. The results
obtained showed that the energy effectively transferred to the work piece varies with the discharge current and pulse duration
from 6.5% to 17.7%, which proves that the fixed value assumed in the models is not in line with real EDM process.
Akira Okada et al.(2000) determined the energy distribution using graphite tool electrode by measuring temperature at
different point in work piece, tool and dielectric and later on putting these values in conduction, convection equations. The
convection energy is very less compared to that of conduction, so is neglected. It was concluded that MRR depends upon energy
density and tool wear depends upon adhesion of heat resolved carbon from machining fluid. With increase in discharge current
energy transferred to work-piece increases. Kerosene performs better than de-ionized water as a dielectric in terms of energy
transferred to electrodes. Energy transferred to various parts at different parameter are represented graphically.
III. EXPERIMENT DETAILS

Table 1: Mild steel is chosen as work piece having diameter =9.85mm and Copper as a tool having diameter =9.45mm.Isopropyl alcohol is
used as dielectric fluid.
Properties
Work piece(Mild steel) Tool or electrode (copper)
Melting point ( )
1425 to 1540
1083
Boiling point( )
2862
2570
Density ( )
7.83 g/ cm3
8.9 g/ cm3
272kJ/kg
207 kJ/kg
Latent heat of fusion( )
6090 kJ/kg
4730kj/g
Latent heat of vaporization ( )
Specific heat (C)
0.465 J/g
0 .385 j/g
Thermal conductivity (K)
53.6 w/mk
385 w/mk
A. Experimental Set-Up and Procedure

In this experiment used mild steel as a work piece and cooper as a tool (electrode) both are cylindrical shape experiment were
conducted by using sink EDM. Dielectric fluid used for cooling as well as flushing of wear material during experiment called as
EDM oil, sometime used ordinary fluid such as a kerosene , water etc. but in my experiment used isopropyl alcohol as a EDM
oil. Here used Teflon as a insulating material for work piece and tool so that no energy is transmitted radially through the work
piece and electrode during experiment.
Table 2: Fixed Parameters
Voltage
60V
Pulse off time
10 s
Straight or positive polarity
Polarity
Work piece Anode (positive)
Electrode Cathode (negative)
The temperature at different location of work piece, electrode, and dielectric fluid was measure by j-type thermocouple
having range 0 to 600 degree Celsius. Thermocouple attached with temperature indicator having least count one degree Celsius.
The Thermocouples were inserted in the space provided in the Teflon insulation at points 1,2 around work piece and 3,4 around
electrode at distance of L1, L2, L3 as shown in Fig.2 . T1 and T2 are the temperature of work piece at upper and lower end and
T3 and T4 are temperature of electrode at lower and upper end as shown in Fig.1. Also Thermocouples were fixed in the
suitable arrangement to measure the temperature of dielectric fluid at different locations, Td1 Td2 are the temperature measured
in dielectric fluid.
Table 3: Variable parameters
Discharge current (A) 2
10
18
Pulse duration (s)
50 150 250
Fixed parameter are those which does not varies with every experiment while variable parameter are those parameter
which varies with every experiment so as to find the Optimum parameters where there is a better utilization of energy and
material removal rate as shown in Tables 2and 3 respectively. By using different variable parameter on sink EDM with mild steel
and cooper as a work piece and electrode respectively to perform individual experiment. Temperatures of the individual
measuring points were measured with the help of Thermocouples before each experiment as well as after different machining
duration of the process. The time of machining has been noted on the monitor of the electrical discharge machine or stop watch,
and the observations are given in Tables 4 and 5. The material removal rate MRR, in mm3/min. has been calculated at the time
where steady state temperature is obtained using the results of Tables 4 and 5. The MRR at different current density and at
119

different pulse duration after achieving the steady state condition is given in Table 4. Material removal rate was calculated by
measuring the Weight before and after individual experiment by which calculate weight loss after per unit time which may be
converted into volume per unit time by dividing loss weight per unit time with material density.
Fig. 1:
Current, I(A)
2
2
2
10
10
10
18
18
18
Current I(A)
2
2
2
10
10
10
18
18
18
Fig. 2:
Table 4: calculation of material removal rate (initial temperature=34)

Pulse Duration Ti(s) L1w(mm) L2w(mm) L3w(mm) T1(oC) T2(oC) Td1(oC)
50
19.73
27.48
57.98
52
42
36
150
20.07
27.75
56.04
55
44
37
250
19.96
27.77
56.79
58
45
37
50
19.79
28.45
56.38
51
42
37
150
19.85
27.61
56.81
55
42
38
250
20.28
27.97
52.53
93
52
38
50
19.29
28.11
58.15
69
45
38
150
19.76
28.17
57.49
85
52
39
250
19.67
28.32
55.64
90
54
39
Table 5: calculation of tool wear rate (initial temperature=34)
Pulse DurationTi(s) L1E (mm) L2E(mm) L3E(mm) T3(oC) T4(oC) Td1(oC)
50
20.64
26.50
49.99
59
51
36
150
23.98
24.66
48.59
60
50
37
250
21.63
26.57
49.99
62
51
37
50
21.80
24.72
50.25
58
49
37
150
21.51
25.67
49.03
59
51
38
250
21.46
25.69
49.81
100
69
38
50
20.51
23.74
49.91
69
61
38
150
22.16
26.68
49.25
80
71
39
250
22.53
24.56
49.15
94
70
39
Td2(oC)
34
34
34
34
35
35
35
36
35
Vw (mm3/min)
1.4097
2.2098
0.9797
16.0975
20.7670
19.7670
14.6687
22.6810
25.2893
Td2(oC)
34
34
34
34
35
35
35
36
35
VE(mm3/min)
0.3507
0.5611
0.1804
2.1918
0.8328
1.4466
3.8576
3.3006
0.7014
1) Analysis of Variance (ANOVA) for SN ratios

Experiment No.
1
2
3
4
5
6
7
8
9
Table 6: MRR and TWR and their correspondence SN ratio

Peak Current Pulse on Time
MRR
SN Ratio for MRR
TWR
2
50
1.4097
2.9825
0.3507
2
150
2.2098
6.8871
0.5611
2
250
0.9797
-0.1781
0.1804
10
50
16.0975
24.1352
2.1918
10
150
20.7670
26.3475
0.8328
10
250
19.7670
25.9188
1.4466
18
50
14.6687
23.3278
3.8576
18
150
22.6810
27.1132
3.3006
18
250
25.2893
28.0587
0.7014
SN Ratio for TWR

9.1013
5.0192
14.8753
-6.8160
1.5892
-3.2070
-11.7263
-10.3719
3.0807
120

Fig. 3: Mean effect plot for MRR
The above main effects plot for means shows the relation between the parameters of EDM and MRR. Both the plots show that
with increase in process parameters the value of MRR increases. At initial level of parameters, the MRR increases gradually but
with further increase in the level of current and pulse on time, the value of MRR increases at a very slow pace.
Peak Current is the most dominating factor and it can be seen from the plot that the MRR increases at a higher rate as
compared to pulse on time. The MRR increases because, with increase in the value of peak current, the intensity of spark
increases and hence large craters are formed on the work piece which results in higher MRR at higher value of parameters.
Fig. 4: Mean effect plot for TWR
The above main effects plot for means shows the relation between the parameters of EDM and TWR. The first plot shows
the relation between TWR and Current, which indicates that with increase in current the value of TWR increases. This is due to
the fact that the intensity of spark increases with increase in the level of Current and hence the TWR increases. Peak current is
the most dominating parameter for TWR.
Pulse of time is the second most dominating factor for TWR. Its seen from the plot that TWR decreases with increase in
pulse on time. This is because with increase in pulse on time, the intensity of spark decreases and hence the TWR decreases.
Table 7: Response Table for Signal to Noise Ratios for MRR (Larger is better)
Level
I
Ton
1
3.230 16.815
2
25.467 20.116
3
26.167 17.933
Delta 22.936 3.301
Rank
1
2
121

Table 8: Response Table for Signal to Noise Ratios for TWR (Smaller is better)
Level
I
Ton
1
9.665 -3.147
2
-2.811 -1.254
3
-6.339 4.916
Delta 16.004 8.063
Rank
1
2
Table 9: ANOVA for MRR
Source DOF
SS
Adj MS
F
Contribution %
I
2
679.12 339.56 41.69
90.16
Ton
2
41.56
20.78
2.55
5.52
Error
4
32.58
8.14
4.32
Total
753.25
It is seen from ANOVA that the contribution of Peak Current is highest and is 90.16% and it is the most dominating
factor for MRR followed by Pulse on time with a contribution of 5.52%.
Source
I
Ton
Error
DOF
2
2
4
Total
Table 10: ANOVA for TWR

SS
Adj MS
F
7.6330
3.8165 41.69
2.7874
1.3937
2.55
3.8876
0.9719
Contribution %
53.35
19.48
27.17
14.3079
Its seen form the above table that the contribution of Peak current for TWR is highest and is the major influencing
parameter with a contribution of 53.35% while the contribution of pulse on time is only 19.48%.
2) Analysis of Energy
The input energy per unit time is as follows:
= V*I*DF*
Where
V = Input voltage
I = Supply current in ampere
DF = Duty factor
= Relative frequency
3) For Work Piece
Energy loss due to heat conduction into work piece is given by
(
Energy carried away by worn debris of work piece is given by

(
)
* (
)
)
4) For Electrode
Energy loss due to heat conduction into electrode is given by
(
Energy carried away by worn debris of electrode is given by

(
)
* (
Heat convection from dielectric fluid is given by
=
(Tm Ta)
As = surface area
The residual energy Q9 is given below:
Input total energy
Current (A)
2
2
2
10
10
Pulse Duration
Ti(s)
50
150
250
50
150
)
)
Table 11:
Energy transfer to Work piece(W) Energy transfer to Electrode(W)
Econd
Edeb
Econd
Edeb
1.48556
1.4129
8.1478
0.30762
1.61822
2.2147
10.9446
0.49217
1.91106
0.9819
11.1737
0.15824
1.29142
16.1335
9.8263
1.92253
1.92213
20.8134
8.4112
0.73049
Energy transfer to Dielectric fluid(W)

21.9919
23.8398
23.8398
23.8398
27.6214
122

10
18
18
18
250
50
150
250
Win (Input electrical

energy)
100.00
100.00
100.00
562.50
562.50
562.50
1038.46
1038.46
1038.46
5.98409
3.48544
4.78227
5.18939
19.8112
14.7015
22.7317
25.3458
32.5680
1.26888
9.0950
3.38369
9.1044
2.89512
26.3741
0.61523
Table 12:
Energy distributed into
Energy distributed into
% of Energy distributed into
work piece
electrode
work piece
2.8984
8.4554
2.89841
3.8330
11.4368
3.83296
2.8929
11.3319
2.89295
17.4249
11.7488
3.09776
22.7355
9.1417
4.04188
25.7953
33.8369
4.58583
18.1869
12.4787
1.75134
27.5140
11.9995
2.64950
30.5352
26.9893
2.94043
Table 13:
Energy distribution ratio in fraction
Work piece
Electrode
Dielectric fluid
Econd
Edeb
Econd
Edeb
0.0148556 0.0141285 0.081478 0.0030762
0.366532
0.0161822 0.0221474 0.109446 0.0049217
0.283808
0.0191106 0.0098189 0.111737 0.0015824
0.220739
0.0022959 0.0286817 0.017469 0.0034178
0.056762
0.0034171 0.0370016 0.014953 0.0012986
0.051151
0.0106384 0.0352199 0.057899 0.0022558
0.092071
0.0033564 0.0141570 0.008758 0.0032584
0.028417
0.0046052 0.0218898 0.008767 0.0027879
0.058351
0.0049972 0.0244071 0.025397 0.0005924
0.039091
27.6214
27.6214
31.5096
29.5527
% of Energy distributed into
electrode
8.4554
11.4368
11.3319
2.0887
1.6252
6.0155
1.2017
1.1555
2.5990
B. The Variations of Energy Distribution Ratios with Discharge Current
Fig. 5:
123

Fig. 6:
Fig. 7:
IV. CONCLUSION
Following conclusions can be drawn from the analysis of the results:
1) Machining rate increases with the increase in current due to predominant increase in spark energy. Current is the most
significant factor for MRR while pulse duration and duty factor has less significant factor for MRR.
2) Energy distributed into electrode is higher than energy distributed into work piece at lower current but it vice versa for
higher current, distributed energy include both conduction energy & energy carried away by debris. Energy distribution
increase with pulse duration for both work piece and electrode.
3) Energy transfer into work piece increase with increasing current while in case of electrode energy transfer decrease with
increasing current.
4) The energy loss due to conduction into electrode is larger than that into work piece regardless of the discharge duration, As
the pulse duration is shorter the energy loss due to conduction into electrode and work piece becomes larger.
5) The ratios of energy distributed into electrode and work piece are almost constant regardless of discharge duration. The ratio
of energy distributed into work piece becomes larger with an increase of discharge current.
6) Material removal rate mainly depends upon some constant parameter such as thermal conductivity, melting points of
material, and dielectric fluid properties , because of low thermal conductivity of material has ability to transfer conduction
energy is also low at steady state which result rate of cooling at spark end slower cause higher material removal rate.
Material having low melting point required less energy to melt (or evaporate).
124

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GRD Journals- Global Research and Development Journal for Engineering | Volume 1 | Issue 12 | November 2016