Abstract
In the current study, an optimization process of powder-mixed electrical discharge machining (PMEDM) process when machining cylindrically shaped parts made of hardened 90CrSi steel is reported. In this study, SiC powder was mixed into the Diel MS 7000 dielectric solution. Additionally, graphite was chosen as the electrode material. The multi-objective functions were minimizing the surface roughness (SR) and electrode wear rate (EWR) and maximizing the material removal rate (MRR). The used input parameters of the optimization process included the powder concentration, the pulse-on time, the pulse-off time, the pulse current, and the servo voltage. A combination between the Taguchi method and the grey relation analysis (GRA) method with the support of Minitab R19 software was used to design the experiment and analyze the results. It was found that the optimal set of process parameters that can satisfy the above responses are Cp of 0.5 g/L, Ton of 8 µs, Toff of 8 µs, IP of 5 A, and SV of 4 V.
Highlights
In order to remove the materials on the surfaces of mechanical parts made of difficultto-cut materials, research communities and industry have successfully applied electrical discharge machining (EDM), an advanced machining process
The appropriateness of the experimental model verified by the Anderson–Darling method in Figure 6 shows that the data corresponding to the experimental points are in the region bounded by two upper and lower bounds with the standard deviation of 95%
The optimal set of process parameters that can minimize surface roughness, electrode wear rate, and maximize material removal rate is found in this study
Summary
In order to remove the materials on the surfaces of mechanical parts made of difficultto-cut materials, research communities and industry have successfully applied electrical discharge machining (EDM), an advanced machining process. Ejecting force of discharge on the melted materials is reduced by extended discharge gaps These reasons significantly impact the lower efficiency of PMEDM machining when compared to that of traditional EDM. Kanssal et al [21] applied the response surface method to plan and analyze the experiments for optimizing the process parameters such as pulseon time, duty cycle, peak current, and concentration of the silicon powder. The responses in this study are minimizing surface roughness and maximizing the material removal rate It shows that peak current factor and concentration are the most influential parameters on MRR and SR. When comparing the effectiveness of each mixed powder material, Narumiya et al [2] reported that under suitably mastered machining conditions, surface quality resulting from aluminum and graphite powders is better than that generated by silicon powder in the dielectric. The optimal set of main process parameters will be confirmed by experiments
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