Abstract
There have been various attempts to improve the surface finish after Electrical Discharge Machining (EDM) by polishing and other means. But if it is possible to improve the surface during machining it will shorten the machining time. From this viewpoint powder mixed EDM (PMEDM) is one of these processes. PMEDM not only imparts fine machined surface finish but also modifies the machined surface. However, it is necessary to understand the mechanism of PMEDM process. In this study, influence of process parameters to tool wear rate (TWR) of PMEDM using titanium (Ti) powder is presented. The objective of the study is to evaluate the main effects of workpiece material, tool material, polarity, pulse-on time, intensity of discharge, pulse-off time, and powder concentration on the TWR in PMEDM. They carried out the investigation based on the Taguchi method involving seven control factors with three levels for an orthogonal array L27 (1313).The results indicated that electrode material, electrode polarity, pulse on time, current and powder concentration were the most significant parameters that influenced the TWR. This result will be the basis for selecting the factors in further optimization studies.
Highlights
Electrical Discharge Machining (EDM) is a non traditional machining process that has become a well established machining option in manufacturing industries throughout the Manuscript Received on April 11th, 2017, Manuscript Revised November 14th, 2016world and has replaced drilling, milling, grinding and other traditional machining operations
The results show that powder mixed EDM (PMEDM) can distinctly improve the surface finish and surface quality
The intent of the present study is to study the effect of different input parameters, namely, workpiece material, tool material, polarity, pulseon time, current, pulse-off time, and powder concentration and some their interactions on the tool wear rate (TWR) in PMEDM using Ti powder
Summary
EDM is a non traditional machining process that has become a well established machining option in manufacturing industries throughout the Manuscript Received on April 11th, 2017, Manuscript Revised November 14th, 2016world and has replaced drilling, milling, grinding and other traditional machining operations. With the continuous process improvement in EDM, the demand for high machining precision with low surface roughness at relatively high machining rates arise in die, mold and tool manufacturing industries. To fulfill this requirement a relatively new advancement in the direction of process capabilities is the addition of powder in the dielectric fluid of EDM. Prior research has shown that, a suitable powder is mixed into the dielectric fluid used in EDM, which can lead to both an increased material removal rate (MRR) and TWR is reduced. Many researchers used metal powder in the kerosene dielectric fluid and investigated the various effects on the machining parameters such as surface roughness, TWR, material removal rate. It is observed that the improvement of EDM efficiency by PMEDM is still at the experimental stage
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