Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

Abstract

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

Prediction of Material Removal Rate in Die-sinking Electrical Discharge Machining

“…The dependence of MRR to the charge Q is shown in Figure 4a where log MRR and log Q is proportional. Increasing either or both I p and t on would improve MRR while compromising the EDM'ed surface finish (Bobbili et al, 2015;Goswami et al, 2014;Sultan et al, 2014). Data analyzing using Minitab utilizes the charge Q as a variable instead of peak current and on-time separately.…”

“…Higher MRR was observed when wire-EDM material with low melting temperature and low electrical resistivity. Sultan et al (2014) published their study of die sinking EDM using copper tube electrode on EN353 steel workpiece. Box-Behnken design was used for planning and executing main experimentation with on-time, off-time, and peak current as the input parameters.…”

Experimental investigation on the effect of SiC particles in machining process of Al–5.3%CU-SiCp–Al2O3p hybrid nanocomposite by EDM

“…It should be noted that the weighing operation was carried out using a digital scale of 0.0001 g for tools and all composite parts. By obtaining data from the weighing process and machining time, the MRR and the TWR was also calculated [17]. The critical point to be noted here is that the drying process of parts in the furnace for 24 h after machining and before the weighing process, to avoid the moisture does not interfere with the results.…”

Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

“…For investigating the influence of process parameters on productivity, cost and quality of electric discharged machined part, it can be observed from figure 1 that current, pulse on time (Pon) and pulse off time (Poff) are widely applicable process parameters as identified by researchers. Literature also suggests that the current and Pon has a direct influence on MRR, EWR and SR; all three performance measures increase when current is increased [7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26]. Whereas, Pulse off time exhibits inverse effects that are, MRR, EWR and SR decrease at higher Poff [19,25].…”