Optimization of process parameters of EDM used to machine D2-die steel

Dewangan, Saurabh; Kumar, Nikhil; Saini, Deepankar; Singh, Vishal

doi:10.1016/j.matpr.2022.10.051

Cited by 2 publications

(1 citation statement)

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“…Similarly, the most cogent parametric combination has been proposed by Sharma et al [ 11 ] to machine nickel alloys 625 and 718 for the optimized MRR, TWR, surface roughness, and overcut. Optimization of EDM parameters for different materials have also been reported, such as for AISI 329 steel [ 12 ], SAE 304 [ 13 ], and D2-die steel [ 14 ].…”

Section: Introductionmentioning

confidence: 99%

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

et al. 2023

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Electric discharge machining is relatively a slow process in terms of machining time and material removal rate. The presence of overcut and the hole taper angle caused by the excessive tool wear are other challenges in the electric discharge machining die-sinking process. The areas of focus to solve these challenges in the performance of electric discharge machines include increasing the rate of material removal, decreasing the rate of tool wear, and reducing the rate of hole taper angle and overcut. Triangular cross-sectional through-holes have been produced in D2 steel through die-sinking electric discharge machining (EDM). Conventionally, the electrode with uniform triangular cross-section throughout the electrode length is used to machine triangular holes. In this study, new designs of electrodes (non-conventional designs) are employed by introducing circular relief angles. For material removal rate (MRR), tool wear rate (TWR), overcut, taper angle, and surface roughness of the machined holes, the machining performance of conventional and unconventional electrode designs is compared. A significant improvement in MRR (32.6% increase) has been achieved by using non-conventional electrode designs. Similarly, the hole quality resulted by non-conventional electrodes is way better than hole quality corresponding to conventional electrode designs, especially in terms of overcut and hole taper angle. A reduction of 20.6% in overcut and a reduction of 72.5% in taper angle can be achieved through newly designed electrodes. Finally, one electrode design has been selected (electrode with 20 degree relief angle) as the most appropriate electrode resulting in better EDM performance in terms of MRR, TWR, overcut, taper angle, and surface roughness of triangular holes.

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