IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 03, 2015 | ISSN (online): 2321-0613 All rights reserved by www.ijsrd.com 3200 Parametric Optimization of Electro Discharge Machining Process for MRR, Micro Hardness and Surface Roughness Patel Umesh K 1 Prof. Vidhya Nair 2 1,2 Department of Mechanical Engineering 1,2 LDRP – ITR, Gandhinagar Abstract— The Electro Discharge Machining is a widely accepted non-convection machining process. There are so many process parameters which are statistically affects the machining. Best combination of these parameters gives excellent result. For current research pulse on time, pulse off time, peak current and spark gap set voltage is selected to optimize material removal rate. Surface roughness and micro hardness is also optimizing for better result. The analysis is based on Response surface Methodology. Keywords: E.D.M., Taguchi Technique, ANOVA, Surface Finish, MRR I. INTRODUCTION Electrical Discharge Machining is a one type of Non- convectional machining Process. Non-convectional processes are design to machine hard material and to produce complex shapes which are not economical to produce by convectional method. These methods become more popular with the employment of CNC facilities. Electrical Discharge Machining is most popular to make very fine hole. Die sinking EDM and Wire EDM are two widely used method of Electrical Discharge Machining. Generally Wire Electrical Discharge Machining is used to cut complex shape. These methods have found successful applications in several important industries for machining of components having complicated shapes made of hard materials like tungsten carbides, super-alloys, ceramics, refractory materials as well as common material. Electrical discharge machining (EDM) is one of the most extensively used non conventional material removal processes. Its unique feature of using thermal energy to machine electrically conductive parts regardless of hardness has been its distinctive advantage in the manufacture of mould, die, automotive, aerospace and surgical components. In addition, EDM does not make direct contact between the electrode and the workpiece eliminating mechanical stresses, chatter and vibration problems during machining. Today, an electrode as small as 0.1 mm can be used to „drill‟ holes into curved surfaces at steep angles without drill „wander‟. II. LITERATURE REVIEW So many research papers and articles are survey on EDM those are related to know the effect of process parameter on performance of process. The materials investigated on EDM are most of HSS, other Tool material, Hot Die material, Cold Die material, Nickel alloys and Titanium alloys which are hard compare to other material. These materials are AISI M2, AISI D2, AISI D3, AISI D5, AISI H11, AISI 4140, SKD 11, En 16, En 19, En 31, En 32, 1040, 2379, 2738, Inconel, Ti alloys, Al alloys, 7131 cemented, Tungsten Carbide (WC) etc. Different author use different combination of process parameter. They analyze the experimental data by plotting Interaction graphs, Residual plots for accuracy and Response curves. Some other methods used by different author for analysis of Taguchi‟s DOE data regarding to EDM and EDM are Regression analysis, Response Surface Methodology, Central Composite Design (CCD), Feasible-Direction Algorithm, SA algorithm, Pareto, Artificial Bee Colony (ABC), Grey Relational Analysis, Genetic Algorithm, Fuzzy clustering, Artificial Neural Network, Tabu-Search Algorithm, Principle component method etc. Most of the author used L 27 Orthogonal Array. Generally the effect of Pulse ON time, Pulse OFF time, Spark gap set Voltage, Peak current, Flushing Pressure, Work piece height, wire tension and wire feed on the material removal rate, surface roughness, kerf and gap current is investigated. I found in literature survey that nobody did a process parameter optimization for SS410with Copper Tungsten electrode. SS410is a low alloy high strength alloy steel and Copper Tungsten has low wear rate so for present work this material are selected for analysis and optimization. III. EXPERIMENTAL PROCEDURE The Conventional machining processes were developed to machine the different kind of reinforcements. But they lost their competitive edge to non-conventional machining because of poor surface finish, high tool wear rate and high tooling cost. To Increasing the weight ratio of Copper in has high tensile strength, electrical conductivity and low resistance. Powder metallurgy has been an effective method of producing copper composite material. Tool can be made up of copper and tungsten material. So increase production rate, reduced machining cost, tool wear rate is decreased and improved surface finish of the composite materials. So Copper-tungsten compsite material is selected for current project work. IV. DESIGN OF EXPERIMENTS A. Selection of orthogonal array Three level of variable process parameter is chosen for convenience for experiment and analysis. Based on the literature survey the levels are decided. Table 4 show the process parameter called factor, their symbol, units and range as a machine units and actual units. The following parameters are remaining constant during process:- 1) Tool Material : Copper-Tungsten Composite 2) Work piece Material : SS410 3) Dielectric Fluid : Deionized Water 4) Flushing Pressure : 12 kgf/cm
5
Embed
Parametric Optimization of Electro Discharge Machining ...Die sinking EDM and Wire EDM are two widely used method of Electrical Discharge Machining. Generally Wire Electrical Discharge
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 03, 2015 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 3200
Parametric Optimization of Electro Discharge Machining Process for
MRR, Micro Hardness and Surface Roughness
Patel Umesh K1 Prof. Vidhya Nair
2
1,2Department of Mechanical Engineering
1,2LDRP – ITR, Gandhinagar
Abstract— The Electro Discharge Machining is a widely
accepted non-convection machining process. There are so
many process parameters which are statistically affects the
machining. Best combination of these parameters gives
excellent result. For current research pulse on time, pulse off
time, peak current and spark gap set voltage is selected to
optimize material removal rate. Surface roughness and
micro hardness is also optimizing for better result. The
analysis is based on Response surface Methodology.