EFFECTS OF PROCESS PARAMETER ON

MACHINING OF HC-HCR DIE STEEL BY

EDM USING
COPPER ELECTRODE

SUBMITTED BY :Shyam Sundar (11104879)

Sohil Kumar (11104870)
Sumit kumar (11110667)
Saveen (11104893)

GUIDED BY :Mr. Jaspreet Singh

CONTENTS
Material

removal process
Electrical discharge machining
Equipments and experimental setup
Process parameters
Advantages and disadvantages of EDM
Applications of EDM

CONT
Properties of hc-hcr
Properties of copper
Observations
Result
Conclusions

MATERIAL REMOVAL PROCESS

Shaping operations ot get finished surface by

removing material.

Basically two types :-

Conventional

Non conventional

CONVENTIONAL MACHINING
PROCESS

Tool and work piece are in contact .

Discontinuous or continuous chips are formed.

Examples,Turning,drilling,miling
etc

NON CONVENTIONAL MACHINING

Used for very hard,tough,fragile materials.

Tool and work piece not in contact.

No chips formation,small size debris formed.

EDM,EBM,LBM,AJM,USM,WJM etc.are used

ELECTRICAL DISCHARGE MACHINING

Non conventional type machining.

Machined only electric conductors.

Use spark discharges to erode material.

Cavity formed is of tool shaped used as erosion occurs in confined

area.

Dielectric fluid surrounds both tool and work piece.

Servo mechanism gives gap .005-.001 inch between tool and work
piece.

PRINCIPLE OF EDM

Large number of electrons flow from tool to

job and ions from job to tool.
Such movement visually seen as spark.
kinetic energy of electrons and ions is
converted into heat flux.
This heat flux leads to excess temperature
and melts the metal.
Material removal occurs due to melting.

EQUIPMENTS AND EXPERIMENTAL

SET UP

Dielectricreservoir, pump,circulation system.

Power generator and control unit.
Working tool with work holding device.
X-Y table accomodating working table.
Tool holder,servo mechanism.

SET UP OF EDM

PROCESS PARAMETERS
Peak current
Pulse on time
Pulse off time

PEAK CURRENT : -

in each pulse on
time,current increases untill it reaches a
present level,expressed as peak current.

PULSE ON TIME :- time period during which

machining takes place.

PULSE OFF TIME :- time period during which reionization of dielectric takes place.

ADVANTAGES OF EDM

Machining of complex shapes.

Machining hard materials.
Very high accuracy.
High degree of automation.
Absence of forces.

DISADVANTAGES OF EDM
very slow process.
Predictability of the gap.
Needs electrical conductivity.

APPLICATIONS OF EDM

In aerospace,automative and nuclear industries to

machined very hard metals and alloys.

To machined tough,intricate shape,fragile machining.

PROPERTIES AND COMPOSITION OF HC-HCR DI STEEL

High

dimensional stability.
Wear resistance.
C=1.7 -2%
Cr=12.0%
Si=0.3%
Mn=0.3%

PROPERTIES OF COPPER
Good electrical conductivity.
Good thermal conductivity.
Corrosion resitant.
Ductile.

OBSERVATIONS

RESULT
EFFECT ON M.R.R.
PEAK CURRENT
MRR Increases with increase in current for any value of
pulse on time.
Higher curent makes spark more strong which increases
MRR.
PULSE ON TIME
With longer pulse on duration more material will melt away.
PULSE OFF TIME
Increase in pulse off time results in reduced pulse frequency
due to which reduction in MRR occurs.

EFFECT ON T.W.R.

PEAK CURRENT
Higher current increases pulse energy, which
increases heat energy rate which increases
melting tool and increases TWR.

PULSE ON TIME

TWR increases with increasing pulse on time

because more melting of electrode occurs at
higher pulses due to increase in pulse energy.

PULSE OFF TIME

TWR decreases with increase in pulse off time

because pulse frequency reduces.

EFFECT ON S.R.
PEAK CURRENT
SR Increases with increase in current for any
value
of
pulse on time.
Higher curent makes spark more strong which
increases depth of cut,which increases SR.

PULSE ON TIME
With longer pulse on duration more material will
melt away, hence more SR.

PULSE OFF TIME

Increase in pulse off time results in reduced pulse
frequency due to which reduction in SR occurs.

CONCLUSIONS

For MRR the most significant factor was found to be

peak current followed by pulse on time and the least
significant was pulse off time. The MRR increased
nonlinearly with the increase in current.

For SR the most significant factor was again current

followed by pulse on time and lastly the pulse off
time. SR increased significantly with the increase in
current in a nonlinear fashion. For increase in pulse
on time SR increased.

For less TWR most significant factor is less current

and low pulse on time.

THANK YOU