Optimization of Machining Parameters Using EDM in Gas Media Based on Taguchi Method
TL;DR: In this article, the authors investigated the machining characteristics of gas media used in electrical discharge machining (EDM) and designed process parameters based on Taguchi method to manage the experimental work.
Abstract: The aim of this study is to investigate the machining characteristics of gas media used in electrical discharge machining (EDM). The process parameters were designed based on Taguchi method to manage the experimental work. The main process parameters such as machining polarity, gas pressure, peak current, pulse duration, type of gas media, and servo reference voltage were adopted to explore their effects on machining performance in terms of material removal rate (MRR) and surface roughness (SR) for SKD 61 tool steel. The experimental observed values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters affecting obviously the machining performance were determined by analysis of variance (ANOVA). The optimal combination level of machining parameter for each machining characteristic was obtained by the S/N ratio analysis according to Taguchi methodology.
Citations
More filters
TL;DR: In this article, the current research trends in EDM process containing dry EDM, near-dry, magnetic field assisted, ultrasonic vibrations assisted, and powder mixed EDM processes are reviewed.
Abstract: The process of electrical discharge machining (EDM) is one of the modern machining processes that machining stiff and high-strength parts such as ceramics and heat-treated steels, which traditional methods cannot be successful in their materials removal, is the most important applications of the this process. Deep drilling, machining inclined surfaces and small-scaled machining are the other applications of this process. Despite the unique applications of this method of machining, low materials removal rate (MRR), high surface roughness (SR), high tool wear rate (TWR), formation of recast layer on workpieces surfaces (that is location of defects and cracks) and environmental problems are the main problems and limitations of this process. This paper reviews the current research trends in EDM process containing dry EDM, near dry EDM, magnetic field assisted EDM, ultrasonic vibrations assisted EDM, and powder mixed EDM processes which were developed in order to overcome the limitations of EDM process.
47 citations
TL;DR: In this article, the authors investigated the machining characteristics of a developed hybrid process of electrical discharge machining (EDM) in gas combined with abrasive jet machining and ultrasonic vibration (USV).
27 citations
01 Jun 2017
TL;DR: In this article, the authors investigated the effects of different types of dry electrical discharge machining (EDM) on the performance of a gaseous dielectric in a modification of the oil EDM process.
Abstract: Dry electrical discharge machining (EDM) is a modification of the oil EDM process in which the liquid dielectric is replaced by a gaseous dielectric. This study investigates the effects of differen...
25 citations
Cites methods from "Optimization of Machining Parameter..."
...This method has fewer runs in comparison with other design of experiments methods because of a specially designed regime called orthogonal array.(22) 0 0....
[...]
TL;DR: In this paper, the removal mechanisms of electrical discharge machining (EDM) in gas and ultrasonic vibration were integrated to explore the benefits of the developed hybrid process in improving the machining characteristics.
Abstract: This study integrated the removal mechanisms of electrical discharge machining (EDM) in gas and ultrasonic vibration to explore the benefits of the developed hybrid process in improving the machining characteristics. The developed hybrid process was adopted to determine the machining performances for SKD 61 steel through the experimental investigation. It is well known that using kerosene as a dielectric fluid in EDM would evoke the undesirable problems like fire hazard, air pollution, and environmental damage. In this study, the air, oxygen, and argon gas media were employed in the experiments to investigate the effects on material removal efficiency, surface integrity, and thickness of recast layer. The experimental results show that the hybrid process obtained higher material removal rate (MRR), lower electrode wear rate (EWR), and finer surface roughness (SR). In addition, the oxygen medium could facilitate the reaction within the machining gap to increase the exploding and melting effects. Thus, the MRR obtained by oxygen has the highest values. The argon was an inert gas that could prevent the oxidation during the process, and the lower EWR could be obtained using argon as a medium in the EDM process. The ultrasonic vibration incorporated in the process could effectively reduce the surface defects that were generated on the machined surface. Generally, the different gas media supplied into the machining area could create various mechanisms. The ultrasonic vibration incorporated into the process could also promote the machining performances of the developed hybrid process.
18 citations
01 Oct 2018
TL;DR: In this article, the authors analyzed those properties of EDM which pose a threat to the environment and health of EDDM machine operators as well as presented directions of the development of EDm with respect to its environmental impact and application related characteristics.
Abstract: Electro Discharge Machining (EDM) is one of the most popular methods of shaping objects, used mostly for surfaces with complex shapes and materials of great hardness which are difficult to machine. An increasing interest in machining processes and their influence on the natural environment and operators’ health has led to research aimed to decrease their negative impacts by designing new machining modes or modifying the existing ones. The article analyzes those properties of EDM which pose a threat to the environment and health of EDM machine operators as well as presents directions of the development of EDM with respect to its environmental impact and application related characteristics.
14 citations
References
More filters
TL;DR: In this paper, electrical discharge machining (EDM) can be achieved in gas with the help of a high-pressure gas flow supplied through a thin-walled pipe electrode, which can be removed and flushed out of the working gap without being reattached to the electrode surfaces.
285 citations
TL;DR: A literature survey on the use of dielectric fluids that provide an alternative to hydrocarbon oil is presented in this article, where water-based dielectrics may replace oil-based fluids in die sink applications.
210 citations
TL;DR: In this paper, the authors compared machining characteristics between dry electrical discharge machining, oil EDM milling, and oil die sinking EDM and found that dry EDM is most advantageous to three-dimensional milling of cemented carbide considering the total machining time and cost.
182 citations
TL;DR: In this paper, an ultrasonic-assisted electrical discharge machining (UEDM) method was proposed to improve the efficiency of electrical discharge cutting in gas medium. But, the workpiece material is AISI 1045 steel and the electrode material is copper.
Abstract: This study focuses on using ultrasonic to improve the efficiency in electrical discharge machining (EDM) in gas medium. The new method is referred to as ultrasonic-assisted electrical discharge machining (UEDM). In the process of UEDM in gas, the tool electrode is a thin-walled pipe, the high-pressure gas medium is applied from inside, and the ultrasonic actuation is applied onto the workpiece. In our experiment, the workpiece material is AISI 1045 steel and the electrode material is copper. The experiment results indicate that (a) the Material Removal Rate (MRR) is increased with respect to the increase of the open voltage, the pulse duration, the amplitude of ultrasonic actuation, the discharge current, and the decrease of the wall thickness of electrode pipe; and (b) the surface roughness is increased with respect to the increase of the open voltage, the pulse duration, and the discharge current. Based on experimental results, a theoretical model to estimate the MRR and the surface roughness is developed.
153 citations
TL;DR: In this paper, five EDM models from Snoeys, Van Dijck, Beck, Jilani, and DiBitonto are analyzed in terms of the temperature distribution, crater geometry, and material removal at the cathode.
152 citations