EDM Machining Parameters Research Articles

Enhancing machining efficiency in hybrid metal matrix composites through EDM parameter optimization via grey relational analysis

In summary, this study utilized stir casting to develop three distinct aluminium hybrid composites incorporating boron carbide and alumina. These composites were identified as Al7075 + 12%B4C + 6%Al2O3, Al7075 + 6%B4C + 6%Al2O3, and Al7075 + 6%B4C + 12%Al2O3. The novelty of this research lies in the unique combination of materials and their proportions, offering enhanced properties yet unexplored in this specific configuration. The research focused on machining these composite materials using EDM and employed a Taguchi L27 orthogonal array design to plan the machining tests. Key process parameters considered were gap voltage (V), duty cycle (%), current (A), and different percentages of reinforcement content. This aspect adds a significant novel dimension to the study, as the impact of EDM machining parameters on hybrid composites with this particular composition has not been extensively explored previously. The study applied Grey Relational Analysis to evaluate the impact of EDM machining process parameters on critical output responses, specifically material removal rate (MRR) and tool wear rate (TWR). SEM images revealed redeposited molten material, craters, and surface cracks, emphasizing the importance of controlling discharge energy and current levels for desired surface quality. An optimal configuration was identified peak current 2 A, pulse duration 100 μs, duty factor 20%, Composition 2 for improved surface attributes. These qualitative and quantitative insights inform process optimization strategies for EDM machining of aluminium hybrid composites.

Effect of Wire Electrical Discharge Machining Parameters on various Tool Steels using Grey Relational Analysis

Materials having very high strength are causing hardship to machine using traditional machining methods. Therefore, consequently, unconventional machining process such as ECM, USM and EDM is developed for machining such materials. Wire EDM is an unconventional metal removal technology utilised to produce parts of any profile. Wire EDM machining parameters were optimised using Grey Relational Analysis for machining of tool steels such as H13, D2 and Oil Hardened Non-Shrinking Steels (OHNS). Optimum parameters are identified by conducting L27 OA experiment on H13, D2 and OHNS considering factors like GV, Ton, Toff and the wire feed by Taguchi based GRA method considering MRR, SR and cutting width (kerf) as the performance characteristics. Nine experiments were conducted with each tool. Objective is to obtain maximum MRR, minimum SR and minimum kerf simultaneously. The significance of the machining parameters was determined using ANOVA. From the response table and response graphs, the optimum process parameters were chosen. This method helped to improve the WEDM process.

Optimization of machining parameters in EDM using Taguchi based grey relational analysis

The present investigation optimizes process parameters such tool size, peak current, pulse on time, and dielectric pressure in the EDM process. The material removal rate affects the machining operation's quality. The goal of the present work is to maximize material removal rate using Taguchi technique-based optimization of machining parameters. On an EDM, the experimental study for machining operations was carried out. For EN-31, machining operations are carried out using an orthogonal array with L9. The ANOVA technique was used to evaluate the experimental results. Using a technique called as grey relational analysis, the optimum conditions for material removal rate are determined. The optimum approach for a set of linked parameters is evaluated using the grey relation grade.

Multi-objective optimization using grey relational analysis for wire EDM of aluminium matrix composites

The creation of novel materials with high mechanical qualities necessitates the use of advanced machining techniques. Non-conventional machining processes alter the entire manufacturing scenario. Non-conventional machining processes swiftly replace conventional machining processes for obtaining better surface quality and a higher material removal rate. Based on grey relational analysis, this work proposes an efficacious method for optimising wire EDM machining parameters of AMCs with varied performance characteristics. Stir casting was used to make AMCs (413/B4Cp) using B4C of 3%, 6% and 9% by weight as reinforcement and 413 as the matrix material. In this study, performance features MRR and SR are taken into account while optimising input parameters. The experimented GRG is 0.772, while the anticipated value is 0.784. This method helped to improve the WEDM process.

Analysis of EDM machining parameters for keyway on Ti-6Al-4V alloy and modelling by artificial neural network and regression analysis methods

Analysis of EDM machining parameters for keyway on Ti-6Al-4V alloy and modelling by artificial neural network and regression analysis methods

Identification of the effects and interactions of factors on the EDM process in order to model it using Taguchi method

This article presents the identification of the influence of the effects and interactions of the machining parameters (EDM) of the machine (EROTECH basic 450) in order to model the material removal rate (MRR), the tool wear rate (TWR) and the roughness of the part (Ra). We look at all the machining parameters and collect the effects by the design of experiments method. The modeling carried out is thus carried out by the response surfaces method (RSM). We use the statistical method (ANOVA) analysis of variance to approve the robustness of the models and to verify that they are statistically significant. The Taguchi method was implemented to formulate mathematical models to predict EDM machining parameters. The prediction of responses by empirical models is compared with experimental validation tests and the results are satisfactory.

A Review - Parametric Optimization of Process Parameter for Electro Discharge Machining of Inconel alloy

New materials are coming day by day in to apply to continuous call for plane upkeep, clinical subject and defense for machining complicated shapes. due to improved hardness and high electricity of recent materials, the traditional machining method cannot meet the requirement, so optimization is one of the strategies used in production quarter to arrive for the pleasant production conditions, that's critical want for industries closer to production of excellent products at lower fee. This paper studied the choicest set of method parameters (i.e. material removal charge (MRR), device wear price (TWR), floor roughness) of electric discharge machining for different alloys. The important EDM machining parameters affecting the performance measures of the discharge current, pulse on time, pulse off time, arc hole and obligation cycle. Key Words: Process Parameter, EDM, Microstructure, Optimization.

Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

Flexural, Dry Sliding Wear and Machinability (EDM) Characteristics of AZ91D/TiC (0, 5, 10, 15, & 20 wt%) MMCs

ABSTRACT Weight saving and increase in strength of the material is a challenge for engineers in the automobile sector and aerospace industry. Here, an attempt has been made to analyse the flexural, wear and machinability behaviour of Mg/TiC composites. The optical microscope (OM), SEM, and X-Ray mapping (XRM) were used to determine any defect in the void, distribution and presence and elemental mapping of TiC within the composites. The results of the three-point flexural test show that the maximum flexural strength and flexural strain are obtained at AZ91D/20% TiC composite. The wear test result indicates that with the rise in sliding speed, the wear rate of composites is decreased. The response of EDM machining parameters, such as material removal rate (MRR) and surface roughness (SR), was determined by using both experimental and Taguchi Method. The maximum MRR was obtained at pulse-on time 200 μs, pulse-off time 11 μs, input current 8 amps and 15 wt% of TiC-reinforced Mg alloy. It is also observed that the experimental result of SR is more significant than the predicted value obtained from Taguchi Method.

Influence of optimization techniques and nano surface coating materials on microstructure of iron-nickel-chromium alloy using wire EDM process

Abstract This research proposes developing the new hybrid optimization techniques for getting optimized wire EDM machining parameters and analysing the performance and microstructure of hybrid treatment alloy 20 material (high-velocity oxygen fuel spraying and plasma nitriding on iron-nickel-chromium alloy) after machining in wire EDM. The devising optimization is carried out using back-propagation neural networks (BPNN) integrated with fuzzy logic techniques. Taguchi L27 method uses optimized parameters in 3 factors and 3 level methods to BPNN wire EDM processing parameters. Those processing parameter errors are controlled by applying fuzzy logic system in hybrid optimization techniques. The hybrid optimization provides best results (±5% error) while comparing other techniques. This proposal was started with research review of defined factors and BPNN parameters level for hidden layer number, learning algorithm, neurons numbers, and so on. The analysis of variance (ANOVA), analysis of means (ANOM) and signal to noise (S/N) ratio have been used to identify Taguchi results. The BPNN techniques have been employed significantly to tackle hidden layer's uncertain parameter structures. The fuzzy logic controllers in general have been designed engaging the relations between system performance and factor through error method calculation. The microstructure analysis showed that the no evidence was found of recast layer formation on hybrid treated material after machining in wire EDM due to compressive stress and compound layer on material surface.

Optimization of machine machining parameters in EDM of silicon nitride-titanium nitride based on RSM

EDM of silicon nitride–titanium nitride ceramic composites with copper electrode was carried out here. Input factors of outstanding significance like current (I), spark gap voltage (SV), pulse-on duration (T on ) and pulse-off duration (T off ) were selected to calculate listed technological characteristics. The output responses measured were material abrasion loss (MRR) and electrode abrasion rate (EWR). Also, the distinguishing face of the EDM technique is delved by RSM (Box-Benhken method) based on Design of Experiments (DOE) and experimental results are evaluated by Analysis of Variance (ANOVA). Furthermore, L 29 orthogonal array (OA) based on the DOE to carry a row of machining has been followed here. From experimental outcomes, it is apparent that the current is the highly significant parameter among other factors as it alters both material abrasion loss and electrode abrasion rate. On the other part, difference in the pulse-off duration did not affect the responses. The higher material abrasion loss is obtained when current and pulse-on duration is higher and the increased gap voltage and lower current reduces the EWR. The higher MRR is obtained for current – 6 amps, pulse-on duration – 7 µsec, pulse-off duration – 10 µsec and spark gap voltage – 35 V. Reduced EWR is obtained for current – 4 amps, pulse-on duration – 6 µsec, pulse-off duration – 10 µsec and spark gap voltage – 40 V.

Enhancement of the performance surface roughness of wire cutting process by additives Nano [AL2O3

Experimental investigation and optimization of machining parameters in Wire EDM in terms adding particles Nano-reinforced titanium alloy composite abstracts among the various mechanical processes, the process of manufacturing in wire electrical discharge machines WIRE EDM is one of the most effective and cost-efficient manufacturing processes in the manufacture of titanium alloys Ti-6242. Ti has been dealt with in this article investigate each of operating parameters such as pulse on time, pulse off time, voltage and current insulating liquid with Nano powder [AL2O3] in WIRE EDM compounds titanium alloy. Experiments on titanium alloy carried out with powder mixture with particles size average of [5 nm]. Operating parameters such as voltage, pulse on time and pulse off time are taking into consideration four factors based on the response surface methodology. The performance of thesis evaluated WIRE EDM for ti-6242 using the surface roughness factor SURFACE ROUGHNESS. Quadratic models were developed between parameters and WIRE EDM responses by regression analysis is. The derived mathematical models are then optimized using Box-Behnken optimization based on desire analysis. The search indicates that the expected values of the model obtained to match the experimental values. Improvement in surface roughness is observed in terms of the values obtained from the Box-Behnken analysis.

EDM machining of die steel EN8 and testing of surface roughness with varying parameters

EN 8 belongs to BS 970 standard and is an unalloyed medium carbon steel used for where some better then normal mild steel which is having carbon ranges from 0.3 to 0.6%. The surface roughness of die while machining on EDM machine depends upon the working parameters of the machine. These working parameters will give fine, super fine and coarse roughness surface on the work piece. The main methodology consists of gauging of these parameters and analyzing the surface roughness. For this the experiment has conducted on EDM machine and the surface roughness will be measured and analyzed. Concept of single variable at a time approach at a time will be used to find out the effect of input parameters on the Surface Roughness. A series of experiments would be conducted to study the effects of various machining parameters of EDM. In each experiment, one input variable would be varied while keeping all other input parameter at fixed value. Studies will be undertaken to observe the effect of selected parameters viz; discharge current, T-ON pulse on time, T-OFF pulse off time, wire feed, servo voltage, MRR and Surface Roughness.

Optimization of machining parameters of wire-cut EDM on ceramic particles reinforced Al-metal matrix composites – A review

Abstract Wire-cut Electrical discharge machining process [WEDM] is used in manufacturing industries to machine conductive and hard materials like metal matrix composites, ceramic composites and super alloys, which are having enormous applications in space craft, defense, transportation vehicles, micro systems, farm machinery etc. Aluminum based ceramic particle reinforced metal matrix materials is one of the key factor in producing composites, which enhances mechanical and thermal properties. These Composites (Al-MMCs) owing to having higher strength and stiffness are suitable for variety of engineering applications The current paper reviews the optimization of WEDM machining parameters, responses by deploying different techniques.

Optimization of EDM Machining Parameters to Machine INCONEL – 825

It is observed that in recent trend INCONEL material has tremendous application in aeronautical, aerospace industry and automobile engineering because of its favorable properties. Therefore “Inconel 825” material has been chosen to machine by EDM. But EDM has a disadvantage of lower MRR. So an experimental investigation has been carried out to study machining parameters of EDM to improve MRR and reducing TWR, surface roughness and kerf width. Here heat treatment process has been studied and applied to improve tool life by reducing tool wear rate. In this experiment Copper tool has modified by changing its grain growth structure by step hardening process and results in both heat treated and without heat treated tools are compared.

Optimization of machining parameters of EDM for performance characteristics using RSM and GRA

Optimization of machining parameters of EDM for performance characteristics using RSM and GRA

Measurement of burr removal rate and analysis of machining parameters in ultrasonic assisted dry EDM (US-EDM) for deburring drilled holes in CFRP composite

An ultrasonic assisted dry electrical discharge machining (US-EDM) process in a gaseous fluid medium was proposed to remove the burrs formed on the exit region of a drilled hole. In preliminary experiment, three different electrode tools (copper, brass, and aluminum) were utilized. In secondary experiment, US-EDM and dry-EDM were compared and performed using the copper tool. US-EDM parameters, such as capacitance (C), pulse-on time (TON), and vibration amplitude (Ap-p) were considered as functions of the predicted burr removal rates (BRRs) model. Based on signal to noise (S/N) ratio analysis, machining parameters C=10−2µF, TON=150µs, and Ap-p=4.919µm provided the optimal BRR. The BRR was affected the most by capacitance, followed by pulse-on time and ultrasonic vibration amplitude. The copper tool provided a higher BRR than other tools. US-EDM is considerably effective when TON is low and the performance of US-EDM is better than that of Dry-EDM. Scanning electron microscopy (SEM) analysis showed that the US-EDM method created a heat-affected zone surrounding the machined surface of the deburred exit hole in range of 200µm–500µm.

Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach.

EDM is the most versatile and universally accepted modern machining process having vast application in manufacturing industries. The main drawback of this process is lower machining yield and less dimensional control. In this process the machining rate is independent of the work material hardness as the machining is not due to physical contact between work material and tool. The titanium alloy is an important material having vast application in aerospace and other important engineering and bio-medical field. Due to low machining yield and dimensional control, there is an strict requirement for optimizing the governing machining parameters of EDM. In the present study the process parameters of die-sinking EDM was experimentally, optimized by using full factorial technique for machining titanium grade – V alloy. Peak current, gap voltage, pulse on time and dielectric fluid pressure was taken as input control parameter while material removal rate and surface roughness were taken as response parameters. It was found that peak current and gap voltage are the main control parameters for increasing material removal rate. The scanning electron microscope images of the machined surface were analyzed to determine the effect of increasing control parameter on the response output.

Multiresponse Optimization of Edm Process with Nanofluids Using Topsis Method and Genetic Algorithm

Abstract Electrical Discharge Machining (EDM) process with copper tool electrode is used to investigate the machining characteristics of AISI D2 tool steel material. The multi-wall carbon nanotube is mixed with dielectric fluids and its end characteristics like surface roughness, fractal dimension and metal removal rate (MRR) are analysed. In this EDM process, regression model is developed to predict surface roughness. The collection of experimental data is by using L9 Orthogonal Array. This study investigates the optimization of EDM machining parameters for AISI D2 Tool steel using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. Analysis of variance (ANOVA) and F-test are used to check the validity of the regression model and to determine the significant parameter affecting the surface roughness. Atomic Force Microscope (AFM) is used to capture the machined image at micro size and using spectroscopy software the surface roughness and fractal dimensions are analysed. Later, the parameters are optimized using MINITAB 15 software, and regression equation is compared with the actual measurements of machining process parameters. The developed mathematical model is further coupled with Genetic Algorithm (GA) to determine the optimum conditions leading to the minimum surface roughness value of the workpiece.

Examination of Machining Parameters on the Surface Roughness of Stavax ESR Material Using Electro Discharge Machining

An experimental study was conducted to investigate the effect of EDM die sinking machining parameters on surface roughness of Stavax material for mould insert. The spark gap, peak current and servo voltage were manipulated to find the best combination of EDM machining parameters. The surface roughness of the machined surface of each specimen was measured using Perthometer and the image of texture was observed by using optical microscope. It was observed that the surface roughness was highly affected by the spark gap and peak current whereas the servo voltage had little effect.