Effect of Powder-Mixed Dielectric on EDM Process Performance | ||
| Engineering and Technology Journal | ||
| Article 14, Volume 38, 8A, August 2020, Pages 1226-1235 PDF (1.16 M) | ||
| Document Type: Research Paper | ||
| DOI: 10.30684/etj.v38i8A.554 | ||
| Authors | ||
| Safa R. Fadhil* 1; Shukry H. Aghdeab2 | ||
| 1Production Engineering and Metallurgy Dep. University of Technology, Baghdad, Iraq | ||
| 2Department of Production Engineering and Metallurgy, University of Technology, Baghdad, Iraq, | ||
| Abstract | ||
| Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 μs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 μs, and 10 g/l), and better Ra was (3.51 μm) at (10 A, 50 μs, and 10 g/l). | ||
| Keywords | ||
| Electrical discharge machining; Powder Mixed Electro-Discharge Machining; Response Surface Methodology; Graphite-Silicon Carbide mixing powder | ||
| References | ||
|
[1] K. Ojha, R. Garg, and K. Singh, “MRR improvement in sinking electrical discharge machining: a review,” Journal of Minerals and Materials Characterization and Engineering, Vol. 9, No. 8, pp. 709-739, 2010. [2] G. Raju, K. Santarao, and P. Govindarao, “Influence of powder mixed dielectric EDM on response variables and methods to optimize the response variables: A Review,” International Research Journal of Engineering and Technology (IRJET), Vol. 4, No. 8, pp. 98-103, 2017. [3] R. Sharma and J. Singh, “Effect of powder mixed electrical discharge machining (PMEDM) on difficult-to-machine materials–a systematic literature review,” Journal for Manufacturing Science and Production, Vol. 14, No. 4, pp. 233-255, 2014. [4] S. Kumar, R. Singh, T. Singh, and B. Sethi, “Surface modification by electrical discharge machining: A review,” Journal of Materials Processing Technology, Vol. 209, No. 8, pp. 3675-3687, 2009. [5] H. Kansal, S. Singh, and P. Kumar, “Technology and research developments in powder mixed electric discharge machining (PMEDM),” Journal of materials processing technology, Vol. 184, No. 1-3, pp. 32-41, 2007. [6] A. Singh and R. Singh, “Effect of powder mixed electric discharge machining (PMEDM) on various materials with different powders: a review,” Int. J. Innov. Res. Sci. Technol., Vol. 2, No. 3, pp. 164-169, 2015. [7] A. Erden and S. Bilgin, “Role of impurities in electric discharge machining,” in Proceedings of the Twenty-First International Machine Tool Design and Research Conference, Springer, pp. 345-350, 1980. [8] K. Y. Kung, J. T. Horng, and K. T. Chiang, “Material removal rate and electrode wear ratio study on the powder mixed electrical discharge machining of cobalt-bonded tungsten carbide,” The International Journal of Advanced Manufacturing Technology, Vol. 40, No. 1-2, pp. 95-104, 2009. [9] S. Sharma, A. Kumar, N. Beri, and D. Kumar, “Effect of aluminum powder addition in dielectric during electric discharge machining of hastelloy on machining performance using reverse polarity,” International Journal of Advanced Engineering Technology, Vol. 1, No. 3, pp. 13-24, 2010. [10] S. Assarzadeh and M. Ghoreishi, “A dual response surface-desirability approach to process modeling and optimization of Al2O3 powder-mixed electrical discharge machining (PMEDM) parameters,” The International Journal of Advanced Manufacturing Technology, Vol. 64, No. 9-12, pp. 1459-1477, 2013. [11] M. G. Rathi and D. V. Mane, “Study on effect of powder mixed dielectric in EDM of inconel 718,” International Journal of Scientific and Research Publications, Vol. 4, No. 11, pp. 1-7, 2014. [12] M. Kolli and A. Kumar, “Effect of dielectric fluid with surfactant and graphite powder on Electrical Discharge Machining of titanium alloy using Taguchi method,” Engineering Science and Technology, an International Journal, Vol. 18, No. 4, pp. 524-535, 2015. [13] S. Mohanty, A. Mishra, B. Nanda, and B. Routara, “Multi-objective parametric optimization of nano powder mixed electrical discharge machining of AlSiCp using response surface methodology and particle swarm optimization,” Alexandria Engineering Journal, Vol. 57, No. 2, pp. 609-619, 2018. [14] B. Surekha, T. Sree Lakshmi, H. Jena, and P. Samal, “Response surface modelling and application of fuzzy grey relational analysis to optimise the multi response characteristics of EN-19 machined using powder mixed EDM,” Australian Journal of Mechanical Engineering, 2019. Doi:10.1080/14484846.2018.1564527. [15] R. H. Myers, D. C. Montgomery, and C. M. Anderson-Cook, “Response surface methodology: process and product optimization using designed experiments,” John Wiley & Sons, 3rd ed., 2009. [16] M. K. Pradhan and C. K. Biswas, “Modelling of machining parameters for MRR in EDM using response surface methodology,” National Conference on Mechanism Science and Technology, NCMSTA’08, pp. 535-542, 2008. | ||
|
Statistics Article View: 251 PDF Download: 132 |
||