Experimental investigation and optimization of machining parameters of deep cryogenically treated and tempered steels in electrical discharge machining process

Abstract

Electrical Discharge Machining (EDM) is commonly used as non-traditional manufacturing methods for geometrically complex shaped or hardened materials that are extremely difficult-to-machine with traditional machining processes. In this experimental study, investigations were carried out on the machining of Conventional Heat Treated three different deep cryogenically treated and tempering processes (DCT&T) of AISI 4140 steels in EDM process. The process parameter such as discharge current (9, 16, 23, and 30 A), pulse on time (120, 180, 240, 300 µs) and pulse off time (12, 18, 24, and 30 µs) were investigated and the output responses like surface roughness, electrode wear ratio, material removal rate, and machining time were explored. Experiments were conducted using L16 orthogonal array in EDM machining process. The data obtained from experiments were analyzed. As a result, determination of discharge current (30 Amps), pulse off time (12 to 18 µs), pulse on time (180 to 240 µs) and deep cryogenically treatment with 24 h and 48 h holding time as the optimum machining processing parameters for tempered steels to be subjected to DCT&T process. As a result of multi-criteria optimization, it is suitable for best surface quality and fast material removal rate.

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

“…EDM texturing being an electrical erosion process will not be dependent on the hardness of the tool being machined. 37 Tungsten Carbide was taken as the tool electrode material owing to its excellent wear resistance and high melting point (2870°C) that reduces the tool consumption during the process. Tool diameter of 0.2 mm was selected for fabricating the micro patterns so that the textures developed would have the required dimensions to be classified under the category of micro-machined features according to Scientific Technical Committee of Physical and Chemical Machining Processes of CIRP.…”

Investigation of Mechanical Properties of Aluminum Alloys Welded by Laser Welding and Optimization of Welding Parameters Using Taguchi and ANOVA Methods

“…Optimizasyon yöntemleri arasında en çok kullanılan yöntemlerden biri ise Taguchi yöntemidir. Taguchi yöntemi, basitlik, uygulanabilirlik ve maliyet-etkin çözümler sunması gibi birçok avantajı ile diğer optimizasyon yöntemleri arasında dikkat çekmektedir [21][22][23]. Çalışma kapsamında, ASTM standartlarına göre hazırlanan numunelerin çekme testlerinden en yüksek değerde çekme dayanımı değeri beklendiğinden En büyük değer en iyi ("Larger is better") fonksiyonu kullanılmıştır.…”

Optimization of Welding Parameters of AISI 431 and AISI 1020 Joints Joined by Friction Welding Using Taguchi Method

“…Regression analyses are carried out to analyse and model different variables that have a relationship between the dependent variable and the independent variables (one or more) [26,27,[35][36][37][38][39][40][41][42]. In this study, equations were found by regression analysis for the estimation of axial shortening and tensile strength.…”