International Journal of Production Technology and ManagementTECHNOLOGY (IJPTM), ISSN 0976 AND 6383 INTERNATIONAL JOURNAL OF PRODUCTION (Print),

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EXPERIMENTAL INVESTIGATION OF MACHINING PARAMETERS OF ELECTRIC DISCHARGE MACHINE ON TUNGSTEN CARBIDE (K-10)
Er. RAVINDER KHANNA1, Er. SUMIT GARG2
1 2

(Mechanical Engineering, PCET, Lalru/Punjab Technical University, Jalandhar) (Mechanical Engineering, PCET, Lalru/Punjab Technical University, Jalandhar)

ABSTRACT Machining of hard metal is very difficult process by conventional method. So we use a non conventional method for hard material the method is known as electrical discharge machining (EDM) process. And the material for machining is tungsten carbide (k-10). Where the composition of that material is (94% of W & 6% of C)? Electrical discharge machining (EDM) is one of the most widely used non-traditional machining processes. Electrical Discharge Machining (EDM) is the process of machining electrically conductive materials by using precisely controlled sparks that occur between an electrode and a workpiece in the presence of a dielectric fluid. The electrode may be considered the cutting tool. This paper investigate about the effect of EDM parameters using pulse on time, pulse of time, current and voltage on material removal rate (MRR) . In the present Work we take copper as electrode. Using Taguchi method, an L16 orthogonal array is used in the experiment and four levels corresponding to each of the variables are taken. Keywords: EDM, metal removal rate (MRR), Taguchi method, Tungsten Carbide (WC) 1. INTRODUCTION Electrical Discharge Machining (EDM) is a well-known machining technique since more than fifty years. Nowadays it is the most widely-used non-traditional machining process, mainly to produce injection molds and dies, for mass production of very common objects. It can also produce finished parts, such as cutting tools and items with complex shapes. EDM is used in a large number of industrial areas: automotive industry, electronics, domestic appliances, machines, packaging, telecommunications, watches, aeronautic, toys,
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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

surgical instruments. The principle of EDM is to use the eroding effect of controlled electric spark discharges on the electrodes. It is thus a thermal erosion process. The sparks are created in a dielectric liquid, generally water or oil, between the workpiece and an electrode, which can be considered as the cutting tool. There is no mechanical contact between the electrodes during the whole process. Since erosion is produced by electrical discharges, both electrode and workpiece have to be electrically conductive. Thus, the machining process consists in successively removing small volumes of workpiece material, molten or vaporized during a discharge. The volume removed by a single spark is small, in the range of 10-6-10-4 mm3, but this basic process is repeated typically 10000 times per second. Electrical discharge machining (EDM) is a process that is used to remove metal through the action of an electrical discharge of short duration and high current density between the tool and the workpiece [12]. Both tool and work piece are submerged in a dielectric fluid .Kerosene/EDM oil/deionized water is very common type of liquid dielectric although gaseous dielectrics are also used in certain cases. Tungsten carbide (WC) is an important tool and dies material, mainly because of its high hardness, strength and wears resistance over a wide range of temperatures. It has a high specific strength and cannot be easily processed by conventional machining techniques. Tungsten carbide is a type of cemented carbide; the particles of carbide are bound by the process of powder metallurgy [3-5] to produce tungsten carbide (WC). 2. EXPERIMENTATION PROCESS A number of experiments were conducted to study the effects of various machining parameters on EDM process. These studies have been undertaken to investigate the effects of current (Ip), pulse on time (Ton), pulse off Time (Toff) and voltage (v). The selected work piece material for the work is tungsten carbide. The tungsten carbide has (94% of W & 6% of C).The material for the electrode is copper. Have a diameter of 6mm. Experiments are conducted on brand Elektra model number es 5535 Die Sinking Machine. Physical Properties of Tungsten Carbide Properties Tungsten carbide (Wc) Melting point 2,800 Oc Density Thermal expansion 5 10-6 Oc Hardness Elastic modulus 648 Gpa

14.5 g/cm3

93.7 (HRA)

In the experiment we calculate the MRR and for the calculation of MRR we have to measure the weight of workpiece after every run of experiment. Every time the material is removed from the workpiece due to heat generated by the arc, the remove debris from the workpiece as a result of that the weight of the workpiece decreases. to measure the initial and final weight of workpiece.

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

3. DESIGN OF EXPERIMENTS AND ANALYSIS 3.1 Design of Experiments The experimental layout for the machining parameters using the L16 orthogonal array was used in this study. Table no. 3.3.1 Input Machining Parameters S.NO . 1. 2. 3. 4. INPUT PARMETERS Current (Ip) Pulse on time (Ton) Pulse off time (Toff) Voltage(V) LEVEL 1 10 50 3 20 2 13 100 6 30 3 17 150 9 40 4 20 200 12 50 OBSERVED VALUE Material removal rate (MRR) In g/min.

This array consists of four control parameters and four levels, as shown in table no. 3.3.1. In the taguchi method, most all of the observed values are calculated based on higher is the better. Each experimental trial was performed with three simple replications at each set value. Next, the optimization of the observed values was determined by comparing the standard analysis and analysis of variance (ANOVA) which was based on the taguchi method. 3.2 Results and analysis of MRR for machined surface The effect of parameters i.e. Current, Pulse on time, Pulse off time and Voltage some of their interactions were evaluated using ANOVA. A confidence interval of 95% has been used for the analysis. To measure Signal to Noise ratio (S/N ratio) calculated by the formula

(S/N) HB = -10 log (MSDHB) For material removal rate (MRR) the S/N ratio is larger is better. Where MSDHB = Mean Square deviation for higher the better response. 3.3 Observation table During the conduction of all the 16 experiments with different set of input parameters observation were made for the weight lost in the gram from the workpiece in each experiment and time taken in the minute for the machining of each experiment was also observed. For all the readings time taken was 1 hour. After the completion of all the experiments the observation reading of the weight loss and time taken were filled in orthogonal array as shown in table 3.3.1

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

SR NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Ip (A) 10 10 10 10 13 13 13 13 17 17 17 17 20 20 20 20

Table no. 3.3.1 Average Table for MRR for Material Ton Toff Voltag MRR S/N (s) (s) e (gm/min) Ratio (V) M1 M2 M3 50 3 20 0.0015 0.0013 0.0013 -57.2867 100 6 30 0.0047 0.0028 0.0016 -50.3616 150 9 40 0.0023 0.0016 0.0038 -51.8126 200 12 50 0.0035 0.0025 0.0033 -50.1728 50 6 40 0.0047 0.0031 0.0045 -47.7443 100 3 50 0.0095 0.0075 0.0066 -42.0842 150 12 20 0.0023 0.0016 0.002 -54.1254 200 9 30 0.002 0.003 0.0028 -51.7005 50 9 50 0.0078 0.0063 0.0083 -42.5375 100 12 40 0.0025 0.0043 0.0045 -48.4809 150 3 30 0.003 0.0046 0.0035 -48.636 200 6 20 0.0025 0.0016 0.0021 -53.6946 50 12 30 0.0028 0.0053 0.0045 -47.535 100 9 20 0.0031 0.0033 0.0037 -49.456 150 6 50 0.0068 0.008 0.009 -42.0109 200 3 40 0.0037 0.0048 0.0055 -46.6199

MEAN Ratio 0.0013667 0.0030333 0.0025667 0.0031 0.0041 0.0078667 0.0019667 0.0026 0.0074667 0.0037667 0.0037 0.0020667 0.0042 0.0033667 0.0079333 0.0046667

3.4 Analysis of variance MRR: The results were analyzed using ANOVA for identifying the significant factors affecting the performance measures. The Analysis of Variance (ANOVA) for the mean MRR at 95% confidence interval is given in Tables. The variation data for each factor and their interactions were F-tested to find significance of each calculated by the formula. The principle of the F-test is that the larger the F value for a particular parameter, the greater the effect on the performance characteristic due to the change in that process parameter. ANOVA table shows that current, pulse on time, pulses off time, voltage are the factors that significantly affect the MRR. Voltage has highest contribution to MRR. Main effect plot for the mean MRR is shown in the graph which shows the variation of MRR with the input parameters. As can be seen MRR increases with increase in voltage from 20v to 50v. 3.5 Conformation test From mean of each level of every factor we will construct response table for MRR is given below:
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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

Table no. 3.5.1 Response Table for Signal to Noise Ratios (Larger is Better) Pulse on time CURRENT Pulse off time Voltage LEVEL (B) (A) (C) (D) 1 2 3 4 Delta Rank -52.41 -48.91 -48.34 -46.41 6.00 2 -48.78 -47.60 -49.15 -50.55 2.95 3 -48.66 -48.45 -48.88 -50.08 1.63 4 -53.64 -49.56 -48.66 -44.20 9.44 1

Level 1 2 3 4 Delta Rank

Table no. 3.5.2Response Table for Means Current Pulse on time Pulse off time 0.002517 0.004133 0.004250 0.005042 0.002525 2 0.004283 0.0045080 0.004042 0.003108 0.001400 3 0.004400 0.004283 0.004000 0.003258 0.001142 4

Voltage 0.002192 0.003383 0.003775 0.006592 0.004400 1

From above main effect plot of MRR we can conclude the optimum condition for MRR is A4, B2, C2, D4 i.e. Current (20amp.), Pulse-on (100s) and Pulse-off (6 s), Voltage (50V).
Main Effects Plot for SN ratios
Data Means
A -45.0 -47.5 B

Main Effects Plot for Means

Data Means
A 0.006 0.005 0.004 B

Mean of SN ratios

-50.0 -52.5 -55.0 1 -45.0 -47.5 -50.0 -52.5 -55.0 1 2 3 4 1 2 3 4 2 C 3 4 1 2 D 3 4

Mean of Means

0.003 0.002 1 2 C 0.006 0.005 0.004 0.003 0.002 1 2 3 4 1 2 3 4 3 4 1 2 D 3 4

Signal-to-noise: Larger is better

Main Effect Plot for S/N Ratio of MRR

Main Effect Plot for Means of MRR

The table showing the s/n ratio of MRR where we check the value of p which is less than of 0.05 and in the table 0.023 for current and 0.007 of voltage .which have been showing voltage factor have more contribution for removing the material after that current have been giving there contribution for that.

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

Source Current Pon Poff Voltage Residual error Total

DF 3 3 3 3 3 15

Table no. 3.5.3 ANOVA for S/N Ratio of MRR Seq SS Adj SS Adj MS 75.179 17.743 6.378 179.945 4.600 283.845 75.179 17.743 6.378 179.945 4.600 25.060 5.914 2.126 59.982 1.533

F 16.34 3.86 1.39 39.12

P 0.023 0.148 0.397 0.007

Table no. 3.5.4 ANOVA for Mean Ratio of MRR Source DF Seq SS Adj SS Adj MS F Current 3 0.0000135 0.0000135 0.0000045 11.04 Pon 3 0.0000045 0.0000045 0.0000015 3.72 Poff 3 0.0000032 0.0000032 0.0000011 2.59 Voltage 3 0.0000417 0.0000417 0.0000139 34.18 Residual 3 0.0000012 0.0000012 0.0000004 error Total 15 0.0000640 ** Significant at 95% confidence level Seq SS= Sum of squares, DOF= degree of freedom, Adj MS= adjusted mean variance.

P 0.040 0.154 0.228 0.008

square or

3.6 Optimal design for MRR In the experimental analysis, main effect plot of S/N ratio is used for estimating the S/N ratio of MRR with optimal design condition. As shown in the graphs, there are highest values which effect the material removal rate which are the current (A4), pulse-on (B2), pulse off (C2) and voltage (D4) respectively. After evaluating the optimal parameter settings, the next step of the Taguchi approach is to predict and verify the enhancement of quality characteristics using the optimal parametric combination. The estimated S/N ratio using the optimal level of the design parameters can be calculated:

nopt = -49.016 + ( -46.41+49.016) + (-47.60+49.016) + (-48.45+49.016) +(-44.20+49.016) = -39.6114

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 4, Issue 1, January April (2013), IAEME

y2opt = y2opt =

yopt =0.010g/min. As per the optimal level again the experiment is performed as A4, B2, C2 and D4. The Experimental value that is obtained is 0.009g/min. So the value of percentage change is 10%. 4. CONCLUSION In the present study, for EDM process the effect of current, pulse-on time, pulse off time and voltage has been investigated. The effect of input parameter on output response Material removal rate was analyzed for work material tungsten carbide (K-10). L16 orthogonal array based on Taguchi design and ANOVA was performed for analyzing the result. For the MRR, voltage is most influencing factor and then discharge current and after that pulse-on time and last is pulse off time.MRR increases with the increase in the value of voltage. After that current also affect the MRR with increases. Other factors for higher value of pulse on time and pulse off the MRR are highest. REFERENCES
[1] Mahdavinejad, R.A., Mahdavinejad, A., 2005. ED Machining of WC-Co. Journal of Materials Processing Technology 162-163, pp. 637-643. [2] Soo Hiong Lee, Xiaoping Li. 2003. Study of the Surface Integrity of the Machined Workpiece in the EDM of Tungsten Carbide Journal of Materials Processing Technology 139, pp. 315-321. [3] Singh, S., Maheshwari, S., Pandey, P.C., 2004. Some Investigation into the Electric Discharge Machining of Hardened Tool Steel Using Different Electrode Materials. Journal of Materials Processing Technology 149 (1-3), pp. 272-277. [4] George P.M., Raghunath B.K., Manocha L.M., M.W. Ashish., 2004. EDM Machining of Carbon-Carbon Composite-a Taguchi Approach. Journal of Materials Processing Technology 145, pp. 66-71. [5] Lee S.H., Li X.P., 2001. Study of the Effect of Machining Parameters on the Machining Characteristics in Electrical Discharge Machining of Tungsten Carbide. Journal of Materials Processing Technology.115, (3), pp. 344-358. [6] N.Vijayponraj, Dr.G.Kalivarathan and Vettivel.S.C, Investigation Of Mechanical Behaviour In Forming Of Sintered Copper-15%Tungsten Nano Powder Composite, International Journal of Production Technology And Management (IJPTM), Volume 3, Issue 1, 2012, pp. 54 - 60, ISSN Print: 0976- 6383, ISSN Online: 0976 6391. [7] U. D. Gulhane, P. P. Patkar, P. P. Toraskar, S. P. Patil and A. A. Patil, Analysis of Abrasive Jet Machining Parameters on MRR and Kerf Width of Hard and Brittle Materials Like Ceramic, International Journal of Design and Manufacturing Technology (IJDMT), Volume 4, Issue 1, 2013, pp. 51 - 58, ISSN Print: 0976 6995, ISSN Online: 0976 7002.
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