Electrical discharge machine (EDM) is a machining process that is not affected by the toughness or hardness of the sample material but the electrical and thermal conductivity. In EDM process, good surface quality can only be produced if low peak current is used but the machining process will take a long time causing material removal rate (MRR) to be too low. While the accumulated machine debris in the machining zone can cause abnormal discharge and disrupt the material removal process. The present research aims to study the magnetic field effect on MRR, EWR and SR for EDM process improvement. In addition to MRR, electrode wear rate (EWR) and surface roughness illustrate the effectiveness of the EDM process. The installation of magnetic devices in the EDM machining area were implemented and the experiments were conducted using graphite electrode and AISI420 as the workpiece. Permanent magnets having 0.54 Tesla were applied to produce magnetic fields during EDM operations. The presence of this magnetic field also contributes to the effectiveness of the flushing process because the evaporated debris will be attracted and attached to the magnet, then purify the spark gap medium for the next discharge process. Dielectric that stays clean and sparks under magnetic field influence increases the effectiveness of the material removal process. Surface roughness from Ra measurement has recorded 12.6% to 28.1% improvement when magnetic devices were applied on EDM. The spark ignition delays and the refinement of EDM spark enhanced the surface quality compared to conventional EDM. Comparison of images through optical microscopy and SEM also proves that the Magnetic Field Assisted EDM (MFAEDM) method is capable of producing better surface quality. This MFAEDM shows that action to hybridize EDM is necessary to increase EDM competency by attaining both of machining efficiency and high quality of surface integrity.
The thermal effect of the adhesive material of Aluminum Alloy 319 (Al319) on the cutting tool (insert) causes major problems in surface roughness, tool wear, as well as temperature due to the tendency to melt during the cutting process which can lead to the formation of formed edges, inaccuracies of measurement on the workpiece, surface damaged due to oxidation, which can reduce the life of the insert. The objective of this research is to optimize the nozzle cooling system method in the machining performance of Aluminum alloy 319 to achieve good surface roughness, low-temperature reading, and less insert wear by selecting machining parameters appropriate to cutting speed, cutting depth, and feed rate. The variety of orifice nozzle measurements used from nozzles 1.0 mm to 5.0 mm with the use of different machining parameters (cutting and spindle speed and with fixed cutting depth) using on CNC lathe condition. This method is done by the basic reaction surface (RSM), which is one of the alternative methods to minimize the cutting process that can be done at high cutting speed in which the temperature can minimize the formation of wear on the insert. Built-in edges and thermal construction can reduce the roughness of the work surface. The results of this research the smallest orifice nozzle used able to minimize the thermal impact and reduce the temperature that causes the arrangement of lower build edges (BUE). Therefore, better surface roughness, minimum insert use as well as low temperatures can be achieved. This is because the direction of the coolant can be directed at a point that can remove heat from the chips. The use of cutting fluid from the smallest nozzle size and technical conditions in the machining process can also be offered to obtain productivity, high-quality products, lower costs as well as minimize environmental impact (refrigerant waste is generated). This research is very useful to minimize the cost of the machining process budget and also increase productivity in the machining industry and can also decrease the dependency of machine operators on the skills and knowledge available.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.