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Journal ArticleDOI

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics:

TL;DR: In this paper, electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies and attempts are made to enhance material removal rate with a conse...
Abstract: Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a conse...
Citations
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Journal ArticleDOI
TL;DR: This book is concerned with the general problems of measuring, analysing and interpreting random data and also with the planning of experiments and is not biased toward any one field of application.
Abstract: J. S. Bendat and A. G. Piersol London: John Wiley. 1966. Pp. xi + 390. Price £6 15s. This book, which is recommended, is concerned with the general problems of measuring, analysing and interpreting random data and also with the planning of experiments. It is not biased toward any one field of application.

23 citations

Journal ArticleDOI
TL;DR: In this article, the effect of machining parameters on surface roughness, recast layer thickness and surface morphology was analyzed on machined aluminum 6061 alloy with aluminum powder added in EDM oil and using magnetic field.
Abstract: Surface integrity aspects have been recognized as key research areas for manufacturing industries for determining the quality, longevity and reliability of machined engineering components. Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is technological advancement in EDM process where the performance and stability of process increases by adding the suitable conductive powder in dielectric and using magnetic field. Aluminum 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In the present work, the study was conducted on EDM machined aluminum 6061 alloy with aluminum powder added in EDM oil and using magnetic field to analyze the effect of machining parameters on surface roughness, recast layer thickness and surface morphology. The input machining parameters, namely peak current, pulse on duration, pulse off duration, magnetic field and concentration of powder have been varied during the MFAPM-EDM process. Box–Behnken design approach of response surface methodology (RSM) was employed for experimental design to carry out the experiments. Quadratic model for predicting the surface roughness and recast layer thickness was developed using analysis of variance and regression analysis. Improvement in surface roughness and recast layer thickness were observed on machining with MFAPM-EDM process. Surface roughness and recast layer thickness were mostly influence by peak current and pulse on duration followed by concentration of powder and magnetic field. The surface morphology witness lesser cracks, voids, crater and molten debris particles present on the surface of machined aluminum 6061 alloy.

22 citations


Cites methods from "Comparative evaluation of powder-mi..."

  • ...A model for the output responses in relation to machining parameters can be illustrated utilizing Equation (2)....

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  • ...The SEM image obtained then was image imported into ImageJ software for calculation of RLT and is calculated using Equation 4 (Ref 31, 32)....

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  • ...The quadratic model for SR and RLT with respect to significant machining parameters in actual form is presented in Equation (5) and (6)....

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  • ...The second-order model Y can be written as in Equation (3)....

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  • ...The relationship between actual and coded value for Table 1 can be related using Equation (1) (Ref 14). a ¼ B BmaxþBmin2 Bmax Bmin 2 ðEq 1Þ where a = coded value of machining parameters, B = actual value of machining parameters....

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Journal ArticleDOI
TL;DR: In this article, the authors proposed a die-sinking electrical discharge machining (EDM) is widely used in die and mold-making industry. Finish EDM conditions are often selected to produce good quality surfaces.
Abstract: Die-sinking electrical discharge machining (EDM) is widely used in die and mold-making industry. Finish EDM conditions are often selected to produce good quality surfaces. Attempts to enhan...

14 citations


Cites background or methods from "Comparative evaluation of powder-mi..."

  • ...The values obtained in conventional finish EDM are included within parentheses for experiments No. 3 and 19 only, as the details have been reported in a previous paper (Rajeswari and Shunmugam, 2019a)....

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  • ...In this article, a novel thersholding approach already reported in an earlier paper is followed (Rajeswari and Shunmugam, 2019a)....

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  • ...Two new parameters proposed in the earlier work for analyzing the changes in the gap phenomena during rough and finish conventional die-sinking EDM are also considered in this article (Rajeswari and Shunmugam, 2019a)....

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  • ...The characteristics for the pulse trains shown in Figure 3(a) and (b) are only given in Table 5 under Vb, ti, Vd, Cd and td, since the characteristics of pulses obtained in conventional EDM has been already reported (Rajeswari and Shunmugam 2019a)....

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  • ...These new parameters effectively capture EDM performance in roughing and finishing regimes as reported in a published paper (Rajeswari and Shunmugam, 2019a)....

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Journal ArticleDOI
01 Feb 2020
TL;DR: In this paper, the authors introduced advanced manufacturing techniques such as die-sinking electro-discharge machining, which have been introduced in different industries such as the naval, automotive and product manufacturing.
Abstract: Advanced manufacturing techniques such as die-sinking electro-discharge machining have been introduced in different industries such as the naval, automotive and product manufacturing. The surface f...

11 citations


Cites background from "Comparative evaluation of powder-mi..."

  • ...characteristics of the pulse generated between part and tool is also identified.(7) During the past years, diverse authors carried out their research works about the influence of the dielectric fluid(8) and the main parameters of EDM....

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Journal ArticleDOI
TL;DR: In this paper, the authors proposed an improved concept of occurrence of sparks based on a minimum inter-electrode gap presented by the randomly assigned surface roughness to the tool and workpiece electrodes.
Abstract: The micro-electric discharge machining (micro-EDM) process had been studied by a number of researchers incorporating the single-spark numerical simulation technique. However, due to the stochastic nature of spark generation, complexities arise in determining the precise location of sparks and exact crater overlapping. Owing to this randomness, modelling of the micro-EDM process using the multi-spark approach has not been attempted hitherto. In this research work, an endeavour has been made to propose an improved concept of occurrence of sparks based on a minimum inter-electrode gap presented by the randomly assigned surface roughness to the tool and workpiece electrodes. The inadequacies associated with the single-spark modelling of the micro-EDM process can be overcome to a larger extent by deterministic estimation of the distinct spark location. The essential crater dimensions are inferred from single-spark simulation to estimate the exact number of sparks essential for the removal of a single layer in the multi-spark simulation. Numerically simulated single-crater dimensions are validated with the experimentally determined crater. Further, multi-spark simulation is performed, and successive layers are removed from the workpiece to generate a feature with a certain depth. The effect of the thermophysical properties of workpiece materials (copper, SS-EN 24, and Ti-6Al-4V) on the linear material removal rate (MRRl) is analysed. Simulation results illustrate that among the three materials, Ti-6Al-4V and SS-EN 24 result in the highest and lowest MRRl, respectively. The multi-spark approach presented in this work essentially differs from the occurrence of multiple sparks from a single-pulse input.

11 citations

References
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Journal ArticleDOI
TL;DR: In this paper, the authors show the prospects of electrical discharge machining (EDM) technology by interrelating recent achievements in fundamental studies on EDM with newly developed advanced application technologies.

782 citations


"Comparative evaluation of powder-mi..." refers background or methods in this paper

  • ...that the inter-electrode gap is in the range of 10–100 mm or more depending on the dielectric used and precision required.(10) In certain experiment, graphite powder size of 10 mm is taken and the concentration in dielectric is varied from 0....

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  • ...Kunieda et al.(10) have documented different research issues in EDM in a systematic way....

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  • ...Kunieda et al.10 have documented different research issues in EDM in a systematic way....

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Journal ArticleDOI
TL;DR: In this article, the machining efficiency and surface roughness of powder mixed EDM (PMEDM) was investigated in rough machining. And the results showed that PMEDM machining can clearly improve machining efficiencies at the same time surface roughs by selecting proper discharging parameters.

290 citations


"Comparative evaluation of powder-mi..." refers background in this paper

  • ...Zhao et al.(13) have explained that series of discharges occur at these sites and stream of ions and electrons gets liberated....

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  • ...Zhao et al.13 have explained that series of discharges occur at these sites and stream of ions and electrons gets liberated....

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Journal ArticleDOI
M.L. Jeswani1
01 Aug 1981-Wear
TL;DR: In this paper, a scheme of in-process measurement of graphite contamination, based on measuring the clarity of the kerosene with a photodiode, is proposed, which can be used to detect graphite particles.

236 citations


"Comparative evaluation of powder-mi..." refers background in this paper

  • ...0 g/l to study the material removal in steel workpieces.(12) Since very large size powder particles can bridge the electrode surface and cause short circuiting, it is reasonable to keep the powder size within 20%– 30% of inter-electrode gap....

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Journal ArticleDOI
TL;DR: In this paper, the effect of silicon powder mixing into the dielectric fluid of EDM on machining characteristics of AISI D2 (a variant of high carbon high chrome) die steel has been studied.

222 citations

Journal ArticleDOI
TL;DR: In this paper, the performance improvement of conventional electrical discharge machining with a powder-mixed dielectric was evaluated through quality surface indicators and process time measurements, over a set of different processing areas.
Abstract: Electrical discharge machining (EDM) is a technological process with a large industrial implementation. Its use is particularly intense when very complex shapes on hard materials with a high geometrical and dimensional accuracy are required. However, the technological capability of the process has limited its application when the specification of the part surface quality imposes polished and mirror-like characteristics. The addition of powder particles in suspension in the dielectric modifies some process variables and creates the conditions to achieve a high surface quality in large areas. This paper presents a new research work aiming to study the performance improvement of conventional EDM when used with a powder-mixed dielectric. A silicon powder was used and the improvement is assessed through quality surface indicators and process time measurements, over a set of different processing areas. The results show the positive influence of the silicon powder in the reduction of the operating time, required to achieve a specific surface quality, and in the decrease of the surface roughness, allowing the generation of mirror-like surfaces.

219 citations