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ISSN No:-2456-2165
Abstract:- Electric Discharge Machining (EDM) is an MRR,SR and TW during the EDM machining of Inconel
alternative machining process to traditional machining 600 using copper-carbon, graphite and copper electrodes.
process for the precise machining of complex shaped The maximum MRR, maximum SR and maximum TW
electrically conductive machine parts. The main were achieved with negative polarity. Vaidya and
objective of this research work is to study the impact of Shinde[4] employed Taguchi methodology to optimize the
EDM conditions (Pulse on time, peak current, voltage WEDM conditions for minimum SR and maximum MRR
and types of dielectric) on SR during machining of AISI during the machining of 11 hot die steel using brass
4140 steel using RSM based on face centered design. electrode. The Pon and V were found main influencing
Also an effort is made with optimized EDM conditions parameters for SR while Pon and Poff were found most
to formulate the relationship between machining significant parameters for MRR.
conditions and responses for desired responses. The
SEM analysis has also been carried out to examine the Kumar and Kumar[5] employed Taguchi
surface morphology of machined surfaces of test methodology to study the impact of EDM conditions on
specimens. The pulse on time, peak current, voltage, MRR at the time of machining of mild steel using copper
and types of dielectric are found significant EDM tool. The Ip was found main affecting condition that
conditions that affect the SR. The SR is directly influence the MRR followed by Pon, Poff and V .Dhakad and
proportional to pulse on time & peak current for both Vimal [6] utilized principal component analysis to optimize
Kerosene and deionized water as dielectric fluid. Also, the WEDM conditions For MRR, machining time and gap
the prediction ability of the developed model has been voltage during the machining of 45A Alloy Steel. Among
found significant. the all WEDM parameters, the open voltage was identified
as main influencing parameter. Brar et al.[7]utilized the
Keywords:- EDM , SEM, Surface Roughness, Dielectric Taguchi methodology to optimize the effect of WEDM
Fluid. conditions for minimum SR and maximum MRR during
the machining of aluminum 6061 alloy. For MRR and SR,
I. INTRODUCTION Pon and Ip were found most significant conditions and MRR
increases with increase in Pon and Ip.
Electric Discharge Machining (EDM) is an alternative
machining process to traditional machining process for the Moghaddam and Kolahan[8] employed Taguchi
precise machining of complex shaped electrically methodology to examine the impact of EDM parameters on
conductive machine parts. Now days, due to global MRR, TW and SR during the EDM machining of
competitiveness, manufacturing industries are more AISI2312 steel. The Ip was most significant parameter that
concerned about the quality of their products. During EDM affects the MRR while Pon found most significant parameter
machining, the machining conditions play important role. for SR and TW. Vikash et al.[9] made a comparison
The quality of machined part depends on the proper between two sets of the values of MRR to examine the
selection of the EDM conditions [1]. Therefore, for the impact of carbon during the EDM machining of EN19 and
desired EDM output, judicious selection of the machining EN41steels. The current was found most significant EDM
condition requires. Therefore, many researchers have parameter that affects MRR for both materials. Shashikant
applied different techniques for the optimization of EDM et al.[10] used RSM for the investigation of the impact of
conditions for minimum surface roughness during EDM EDM parameters on SR during the EDM machining of EN-
machining of different materials. 19 steel. The Ip was found most significant parameter for
SR. Das et al. [11] used artificial bee colony algorithm for
Balasubramanian and Senthilvelan [2] used RSM for the selection of optimum EDM parameters for maximum
the study of the impact of EDM conditions on MRR, SR MRR and minimum SR. The predicted and experimental
and TW during the EDM machining of EN8 and D3 steel. values of responses were found are in good agreement to
The high value of MRR and TWR were obtained during the each other. It was also found that SR and MRR increase
machining of D3 steel using cast electrode in comparison to with increase in Pon, and IP.
sintered electrode. Salcedo et al.[3]Investigated the impact
of Pon, Df, type of polarity, type of electrode and Ip on
Levels
The table 2 represents the design matrix for upon the various parameters but most commonly used
experimentation in actual form of EDM conditions. The parameter is surface roughness values. In the present
design matrix contained total 40 numbers of experiments study, center line average (Ra) of the work pieces after the
i.e 20 with kerosene and 20 with de-ionized water. EDM machining was measured making use of a portable
surface tester and the readings were recorded with three
The performance of mechanical parts is based on the times repeated measurements. The measured values of
SR since mechanical properties like tensile strength; center line average (CLA) surface roughness of machined
impact strength fatigue etc. depends on the surface specimens along with design matrix are presented in the
roughness of the machined parts. The SR is calculated table 2.
Table 3 indicates that “Prob. > F” for surface II. INFLUENCE OF EDM CONDITIONS ON
roughness prediction model is less than 0.05, so, model is SURFACE ROUGHNESS
significant. Also,, the “Prob. > F” for V, Ip, Pon, dielectric,
interaction terms of V and Pon, V and dielectric, Ip and Pon, The figure 4 and 5 indicates the variation of SR with
Ip and dielectric, Pon and dielectric are less than 0.05, that respect to voltage during the EDM machining using
shows the SR prediction model along these all terms are kerosene and de-ionized as dielectric respectively. From
significant i.e these all terms have effect on SR. The “Prob. the figures, it was revealed that SR continuously decreases
> F” for lack-of-fit is 0.1682 which is higher than 0.05, so with increase in voltage from 10 to 40 volts. During EDM,
it is insignificant, which is required to model fitting. The R2 metal is removed from the surface of work piece due to
value and adjusted R2 value are 0.991 and 0.989 melting and evaporation. Due to the melting and
respectively, which is very close to each other. Adequate evaporation, craters on the surface of work piece formed.
precision is equal to 91.938 which indicate adequate model The size of craters depends on the energy per spark per unit
discrimination. time[1]. The discharge time increases with increase in
voltage. The higher discharge time will lead to wider
Prediction models average discharge gap. This will decrease the number of
The surface roughness prediction models prediction models discharge cycles within a given period. Hence, it will
are given as: decrease the discharge energy per unit time. Further with
With kerosene decrease in discharge energy, the size of craters also
(𝑆𝑅)0.73 = 0.757 − 0.0202 ∗ 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 + 0.057 ∗ decreases which decrease the surface roughness of
𝑃𝑒𝑎𝑘𝑐𝑢𝑟𝑟𝑒𝑛𝑡 + 0.02 ∗ 𝑃𝑢𝑙𝑠𝑒𝑜𝑛𝑡𝑖𝑚𝑒 − 0.00009 ∗ machined parts [13].
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 ∗ 𝑃𝑢𝑙𝑠𝑒𝑜𝑛𝑡𝑖𝑚𝑒 − 0.00015 ∗ 𝑃𝑒𝑎𝑘𝑐𝑢𝑟𝑟𝑒𝑛𝑡 ∗
𝑃𝑢𝑙𝑠𝑒𝑜𝑛𝑡𝑖𝑚𝑒 (1)
REFERENCES