The different process parameters of edm are shown in the fishbone diagram figure 2 with output parameters mrr, twr and ra. Electrical discharge machining, orthogonal array, signaltonoise ratio, grey relational analysis i. Once that one was discovered by joseph priestly in 1770, in the middle of 1980s machining process on edm were. Experiments were conducted on aisi d2 steel using a copper electrode as the tool. History of edm in1770s, discovered by joseph priestly. In edm, for optimum machining performance measures, it is an important task to.
Three trials are conducted and the average is chosen. Finalizing the levels and preparing a design of experiments plan by using minitab software. Optimization of electrical discharge machining process. However, the process control parameters of the machine have to be set at an optimal setting in order to achieve the desired responses. Electric discharge machining edm processes, process parameters and. Edm process parameters in theory, we can say that the process parameters of edm and the process parameters of microedm are quite similar. The influence of the edm operation on the surface properties of the machined material, can in unfavourintroduction the use of electrical discharge machining edm in the. A brief introduction of the microedm configurations as well as the overview of their capabilities is presented. This is because the working principal is the same which that both of the machining uses electric discharge machining where electrodes discharges pulses and cut away the metal with help of dielectric. For this process to work successfully it is necessary to embed the appropriate directives in. Introduction icroedm is a recently developed process which is used to.
The first edm system was developed by lazarenko in 1943. The process of automating one or more edm machines is similar to that of other conventional machine tools. Due to this wear, tool loses its dimensions resulting in inaccuracy of the cavities formed on the workpiece. This paper presents a study that investigates the effect of the wedm process parameters on the surface roughness average and the kerf width of the stainless steel ss 304. Optimization of electrical discharge machining process parameters using 427 the mrr and twr are calculated using the following expressions.
Parametric optimization of wire cut edm process on aisid3. Machining parameters and their levels taguchi proposed to acquire the characteristic data by using orthogonal arrays, and to analyze the performance measure from the. Processing parameters are not expressly defined in this specification since they are dependent upon the. Hyflex edm files are produced using an innovative manufacturing process called electrical discharge machining figure 2.
Hence, many authors have presented their works on the optimisation of process parameters for various machining processes. Enhancement of material removal rate by using cryogenically treated wire in wire edm process 3 laminate and the wire material on the material removal rate was studied the experiment was carried out on 3 values for the material thickness. Taguchis l27 orthogonal array was used to design the experiments. Analysis of process parameters in wire edm with stainless steel using single objective taguchi method and multi objective grey relational grade. Optimization of the process parameters in microelectric. Introduction the quality of a product is the main factor for showing growth of a company. Analysis of edm process parameters on inconel 718 using. Consequently, during the edm process, the main machining output parameters are the material removal rate mrr, tool wear ratio twr and surface roughness r. Edm process parameters in theory, we can say that the process parameters of edm and the process parameters of micro edm are quite similar. These samples were machined by wire edm cutting, using the same straight pattern, each of 200 mm length. Requirements on microscale machining are addressed. The pulse on time, pulse off time, pulse current and voltage were the control parameters of edm. Optimization of edm process parameters using response.
Optimization of electrical discharge machining parameters. This server has a dns of sagex3appserver the installation is in a directory called d. Thus, pulse on time, peak current and wire tension were selected for investigation work. Process capabilities of microedm and its applications. Optimization of process parameters in wireedm using response surface methodology 17 parameter amongst the parameters selected for the screening experiments. Crosssections of the edm parts are examined using the sem to quantify the recast layer and heataffected zone under various process parameters. Rsm method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a secondaorder response surface. In this work, a modified tool design was adopted to drill holes in the dry edm process. Introduction icro edm is a recently developed process which is used to. Proper selection of machining parameters for the best process performance is still a challenging job.
Secondly, the stateoftheart strategies applied in pulse generation on a commercially available microedm machine are described. This paper presents the optimization of wire electrical discharge machining. Pdf optimization of edm process parameters using taguchi method. Optimization of mrr, surface roughness and kerf width in. The work piece thickness has been considered as the control factor. In this paper, the parameters of electrical discharge machine edm are investigated during the machining of inconel 718 by using different sizes of circular aluminum electrode. Lin et al 1 the application of the taguchi method with fuzzy logic for optimizing the electrical discharge machining process with multiple performance characteristics has been reported. Process parameters optimization of micro electric discharge. Electrical discharge machining edm was not completely in use benefit of this method until 1943. Pdf wire electrical discharge machining is an extremely important machining process among newly developed nontraditional machining.
Analysis and optimization of edm process is difficult task, due to the various complexities in it. The important edm parameters affecting to the performance measures of the process are discharge current, pulse on time, pulse off time, arc gap, and duty cycle 9. The results of the present work reveal that proper selection of input parameters will play a significant role in electric discharge machining. Optimization of machining parameters in wire edm of copper using. However, these optimization techniques have not been used in the optimization of the electrical discharge machining edm. Pdf this paper presents investigation and optimization of electric discharge machining edm parameters using taguchi method. Discharge current i, pulse on time t on, voltage v, pressure p and tool rotational speed n were chosen as the various input parameters. Generally, workpieces are mounted on a pallet system and the automation changes the pallets in and out of a chuck on the machine, said langenhorst. Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to. Optimization of dry edm process parameters using grey. National institute of technology rourkela certificate this is to certify that the thesis entitled parametric optimization of process parameters submitted to the national for edm of stainless.
It consists of eight units divided into several lessons, each designed to meet one of the stated objectives for the unit. Apr 11, 2016 in this work, a modified tool design was adopted to drill holes in the dry edm process. Material removal is directly proportional to the amount of energy applied during this on time. The aim of this paper is to study the influence of pulse on time, pulse off time, gap voltage, peak current and. Dang 11 optimized the edm parameters using a kriging model and particle swarm optimization method,finding that the model and method is suitable for the optimization of edm process. Important parameters of edm a spark on time pulse time or t on. The design of experiment doe analysisbased optimization is the evolutionary algorithms which were used by positively by the various investigators. The electrical energy is directly used to remove or cut the metals. Edm process parameters optimization using taguchi method. Experiments have been conducted with six process parameters. Study of the parameters in electrical discharge machining. Consequently, during the edm process, the main machining output parameters are the material removal rate mrr, tool wear ratio twr and surface roughness. The edm process results in a file that is extremely flexible and fracture resistant.
Machining parameters optimization of wedm process using. Secondly, the stateoftheart strategies applied in pulse generation on a commercially available micro edm machine are described. Electro discharge machining edm, process parametes, performance parameters, optimization, wire cut edm. Pdf optimization of edm process parameters using taguchi.
Electrical discharge machining edm process, even now it is an experience process, wherein still the selected parameters are often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. As edm is very complex and stochastic process, it is very difficult to determine optimal parameters for best machinery performance i. The quality of the product mainly depends upon the material and process parameters. Parameters for opening pdf files you can open a pdf document with a command or url that specifies exactly what to display a named destination or specific page, and how to display it using such characteristics as a specific view, scrollbars, bookmarks, annotations, or highlighting. A brief introduction of the micro edm configurations as well as the overview of their capabilities is presented. Systematic optimization or analysis technique is required to understand and optimize the edm process. Optimization of process parameters in wire edm using response surface methodology 17 parameter amongst the parameters selected for the screening experiments.
International journal of applied mechanics and materials, 2012, 159, 176180. Material is removed from the work piece by a series of rapidly recurring current discharges between two. Pdf experimental investigation of process parameters on. However, the process control parameters of the machine have to be set at an optimal setting in order to. Metal disintegration machining several manufacturers produce edm machines. Consequently, during the edm process, the main machining output parameters are the material removal rate mrr, tool wear ratio twr and surface roughness r a of the workpiece. When established up how the erosive properties of the method could be employed and make use of machining functions. With makino ram edm, no job is too big or too small. Advancements in electrical discharge machining by vishal borkar m. The following procedure is adopted to pursue the optimization of the process parameters. Most extensively used nonconventional, controlled metal removal process that is used to remove metal by means of electrical spark erosion. Electrical discharge machining, orthogonal array, metal removal rate, tool wear rate anova. The process parameters in edm are used to control the performance measures of the machining process.
The process control parameters of the machine have to be set at an optimal setting in order to achieve the desired responses. The manual is for use by students learning electrical discharge machining edm. The parameters considered are pulse current, gap voltage and pulseontime, whereas the responses are electrode wear rate and material removal rate. Optimization of edm process parameters using response surface. In fact, hyflex edm files are up to 700% more resistant to cyclic.
Overview of microedm process parameters in machining. Wedm process parameters such as pulse on time ton, pulse off. It is the duration of time expressed in micro seconds in whom the peak current is ready to flow in every cycle. Dhanabalan and k sivakumar have done edm process optimization with multiple performance characteristics based on orthogonal array with grey relational analysis for titanium grades with brass electrode2.
International journal of technical research ijtr vol. Surfaces of the cylindrical edm parts were examined using scanning electron microscopy sem to identify the macroridges and craters on the surface. Modeling, simulation and parametric optimization of wire edm. Identifying and selection of various process parameters influencing the machining process. Optimization of process parameters of wire edm for. This paper presents investigation and optimization of electric discharge machining edm parameters using taguchi method. Documents in econstor may be saved and copied for your personal and scholarly purposes. By means of the improvement and growths in new mechanisms, low weighthigh strength, high hardness and temperature resistant materials have been advanced for distinctive applications which include aerospace, medical, automobile and more. Electrical discharge machining edm process, even now it is an experience process, wherein still the selected parameters are often far from. Analysis of edm process parameters on inconel 718 using the. Influence of input parameters on characteristics of edm. Six input process parameters of wedm such as spark gap voltage sv, pulseon time t on, pulseoff time t off, wire feed rate wf, peak current ip and wire tension wt and three interactions t on t off, t off sv, t on sv are chosen as variables to study the process performance. Three process parameters chosen were pulse ontime ton, duty factor and discharge current or pulse current. Micro wire electrical discharge machining wedm technology has been.
In this work, response surface modelling rsm is utilized for determining the relations between the various edm process parameters with the various machining criteria and exploring the effect of these process parameters on the responses, i. Edm performance measures such as material removal rate, tool wear rate, and surface roughness are influenced by different process parameters 1. When using the auto destination, pdf files are created by crystal reports passing through a tool which searches for control directives which govern the manner in which the documents contained in the pdf file are to be processed. Influence of input parameters on characteristics of edm process. Input parameters optimization in edm process using rsm and. Demand for better surface finishes are increasing recently for all materials, the low rigidity and high material removal rate of inconel alloys offers a challenging task in obtaining better surface finish. Developed in the mid 1970s in the mid 1980s, the edm techniques were transferred to a machine tool today,it is a viable technique that helped shape the metal working industry.
Optimisation of wirecut edm process parameter by grey. Electrical discharge machining used on hard metals works with electrically conductive materials 3. Parametric optimization of process parameters for edm of. Index terms micro electric discharge machining micro edm, response surface methodology rsm, genetic algorithm ga, twr. Based on the machine tool, cutting tool and work piece capability, the process parameters and the level for the process parameters were selected and listed in table 2. Regulatorysubmissions confidential page 5 of 35 how the reference model came to be implementing an electronic document management edm system typically costs millions of dollars, months if not years of time for customization, and hiring expensive and hardtofind it staff and consultants. Analysis of process parameters in wire edm with stainless. Paper open access related content analysis of effects of.
1020 1257 36 779 1530 1417 86 112 1156 1331 1469 1436 228 1372 1203 666 1257 982 564 682 668 1366 1088 167 1136 1000 1341 379 1096 33 93 789 254 539 1080 1440 54 118 794 1340