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Abstract
The objective of this research study is to investigate the optimal
process parameters of Electric Discharge Machining on RENE80
nickel super alloy material with aluminum as a tool electrode. The
effect of various process parameters on machining performance is
investigated in this study. The input parameters considered are current,
pulse on time and pulse off time are used for experimental work and
their effect on Material Removal Rate, Tool Wear Rate and Surface
Roughness. The Taguchi method is used to formulate the experimental
layout, ANOVA method is used to analysis the effect of input process
parameters on the machining characteristics and find the optimal
process parameters of Electric Discharge Machining. The results of the
present work reveal that proper selection of input parameters will play
a significant role in Electric Discharge Machining.
Keywords: Electrical Discharge Machining, orthogonal array, metal
removal rate, tool wear rate ANOVA.
1. Introduction
Electric Discharge machining (EDM) is a thermo-electric, non-traditional machining
process used to machine precise and intricate shapes on difficult to cut materials and
super tough metals such as ceramics, maraging steels, cast-alloys, titanium which are
widely used in defence and aerospace industries. Electrical energy is used to generate
electrical sparks and material removal mainly occurs due to localized melting and
vaporization of material which is carried away by the dielectric fluid flow between the
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Chandramouli S et al
2. Experimental Details
The experiments were conducted on V3525 precision die sink electric discharge
machine as shown in Fig.1 which consist a work table, a servo control system and a
dielectric supply system. The machine has 8 current settings from 3A to 24A, 9
settings of pulse on time, 9 settings of pulse off time and spark gap of 50-75 microns
The experiments are conducted on RENE80 Nickel Super alloy(Russian grade -RZ)
and the work piece dimensions are 70 mm x 35 mm x 5 mm. Work piece material
properties are: Hardness (HRC)= 43-45, density (g/cm3)=8.16, Ultimate tensile
strength (Kg/mm2) =85, Elongation % =3, Creep strength (0C) = 975. Thermal
conductivity (W/m0K)= 11.50. The tool material used is aluminium- density 2.70
gm/cm3 and thermal conductivity 237 w/m0k and the machining is done with straight
polarity. EDM oil Grade 30 is used as the dielectric fluid and the experiments were
performed for a particular set of input parameters. The number of experiments and,
input levels are decided based on the design of experiments and the input parameters
and their levels are presented in Table 1. The MRR and TWR are calculated using
digital balance of accuracy 1mg and the machining time is using digital watch of
accuracy 1 microsecond and the surface roughness is measured using Taylor Hobson
Talysurf machine for a sampling length of 5mm.
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The MRR and TWR are calculated using the following expressions.
MRR= 1000( Wb- Wa) /t mg/min
TWR= 1000( TbTa ) /t mg/min
Wb : Weight of the work-piece before machining
Wa : Weight of the work-piece after machining
Tb : Weight of the tool before machining
Ta : Weight of the tool after machining
t: Machining time (minutes)
Table 1: Input Parameters Levels.
Input
Parameters
Symbol
Level1
Level2
Level3
Current
(amp)
A
6
15
24
Pulse on
Time (s)
B
10
20
30
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Chandramouli S et al
A
1
1
1
2
2
2
3
3
3
B
1
2
3
1
2
3
1
2
3
C
1
2
3
2
3
1
3
1
2
T1
21
10
6.5
MRR
T2
T3
17
18.5
7
8.5
5.5 16.5
AVG
18.8
8.5
9.5
T1
6
4.8
2.6
TWR
T2
T3
4.5
4
5.6
5.3
3.4
4.3
AVG
4.83
5.2
3.4
SR
AVG
3.67
5.25
3.94
429
121
76.5
56.5
250
180
222
127
73
52
255
150
210
137
113
50
256
165
205
128.3
87.5
52.8
253.6
165
212.3
24.5
13.33
9
49.33
37.16
34.6
25.3
11.5
9.1
50.67
38
35
29
19.3
11
45
31.5
32
26.3
14.71
9.7
48.3
35.5
33.8
4.18
5.15
6.46
5.99
5.94
6.21
Source
Current
Pulse on time
Pulse off time
Residual Error
Total
F
1004.49
71.65
42.71
Source
Current
Pulse on time
Pulse off time
F
82.06
10.78
4.24
F
1.97
0.66
0.07
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Chandramouli S et al
Residual Error
Total
2
8
2.3688
8.7533
1.18441
Current
4.287
5.263
6.047
1.760
1
Pulse on Time
4.613
5.447
5.537
0.923
2
pulse on time
200
150
Mean of Means
100
50
0
6
15
pulse off time
24
10
20
50
10
20
50
200
150
100
50
0
50
pulse on time
Mean of SN ratios
40
30
20
6
15
24
10
20
50
50
40
30
20
10
20
50
40
pulse on time
30
Mean of Means
20
10
0
6
15
24
10
20
50
40
30
20
10
0
10
20
50
-10
pulse on time
-15
Mean of SN ratios
-20
-25
-30
6
15
24
10
20
50
-10
-15
-20
-25
-30
10
20
50
431
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Chandramouli S et al
Main Effects Plot for Means
Data Means
current
pulse on time
6.0
5.5
Mean of Means
5.0
4.5
6
15
pulse off time
24
10
20
50
10
20
50
6.0
5.5
5.0
4.5
pulse on time
-13
Mean of SN ratios
-14
-15
-16
6
15
pulse off time
24
10
20
50
10
20
50
-13
-14
-15
-16
433
7. Conclusion
The result shows that current, pulse on time and pulse off time have significant effect
on MRR,TWR and SR. The results of the present work reveal that proper selection of
input parameters will play a significant role in Electric Discharge Machining.
The MRR is increasing with increase in current.
MRR is decreasing initially with increase in the pulse on time and increasing
later with an increase in pulse on time.
MRR is increasing with increase in the pulse off time but the increase is less as
compared to pulse on time.
TWR is increasing linearly with increase in the current.
The TWR is decreasing with increase in pulse on time, when increase in pulse
off time the TWR is increasing.
The SR is increasing with increase in current and pulse on time but decreasing
with increase in pulse off time.
For optimum MRR, A3B1C3 levels must be selected and for optimum TWR,
A1B3C1 levels and for optimum SR, A1 B1 C3 must be selected.
References
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Chandramouli S et al
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