Optimization of the EDM parameters on machining Ti–6Al–4V with multiple quality characteristics

Kao, J. Y.; Tsao, Chung-Chen; Wang, S. S.; Hsu, Chun-Yao

doi:10.1007/s00170-009-2208-3

Cited by 199 publications

(80 citation statements)

References 15 publications

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“…When voltage increases the electric field gap in a plasma channel also increases and it leads to the presence of larger amounts of electrons and ions. As a result, more ions with a greater deal of energy collide the workpiece and increase surface roughness [14]. 6 shows that since pulse in the time increases frequency decrease and slope of surface roughness increases.…”

Section: Effects Of Input Parameters On Surface Roughnessmentioning

confidence: 99%

“…6 shows that since pulse in the time increases frequency decrease and slope of surface roughness increases. Considering the investigations, it seems that the plasma channel expands at the location of electric arc and inside the dielectric with reduction of frequency or increase in pulse on time in each machining cycle which influences the increase in surface roughness [14]. According to Fig.…”

Section: Effects Of Input Parameters On Surface Roughnessmentioning

confidence: 99%

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Modelling and investigating the effect of input parameters on surface roughness in electrical discharge machining of CK45

2016

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Original scientific paper Electrical discharge machining is an unconventional machining process in which successive sparks are applied to machine the electrically conductive materials. Any changes in electrical discharge machining parameters lead to the pieces with distinct surface roughness. The electrical discharge machining process is well applied for high hardness materials or when it is difficult to use traditional techniques to do material removing. Furthermore, this method is widely applied in industries such as aerospace, automobile, moulding, and tool making. CK45 is one of important steels in industry and electrical discharge machining can be considered as a proper way for its machining because of high hardness of CK45 after thermal operation of the electrical discharge machining process. Optimization of surface roughness as an output parameter as well as electrical discharge machining parameters including current, voltage and frequency for electrical discharge machining of CK45 have been studied using copper tools and kerosene as the dielectric. For such a purpose and to achieve the precise statistical analysis of the experiment results design of experiment was applied while non-linear regression method was chosen to assess the response of surface roughness. Then, the results were analysed by means of ANOVA method and the machining parameters with more effects on the desired outputs were determined. Finally, mathematical model was obtained for surface roughness. Keywords: CK45 steel; current; design of experiments; electrical discharge machining; frequency; non-linear regression; surface roughness Modeliranje i ispitivanje učinka ulaznih parametara na površinsku hrapavost u obradi CK45 električnim pražnjenjemIzvorni znanstveni članak Obrada električnim pražnjenjem je neuobičajeni postupak strojne obrade u kojemu se sukcesivno iskrenje primjenjuje u obradi materijala koji provode elektricitet. Svaka promjena parametara električnog pražnjenja rezultira promjenom površinske hrapavosti uzoraka. Obrada elektičnim pražnjenjem se uspješno primjenjuje kod materijala visoke tvrdoče ili kada se za skidanje čestica teško mogu primijeniti tradicionalne metode. Nadalje, ova se metoda uvelike primjenjuje u aeroindustriji, proizvodnji automobila, oblikovanju, izradi alata. CK45 je važan čelik u industriji i obrada električnim pražnjenjem može se za njega smatrati odgovarajućom zbog postizanja visoke tvrdoće nakon toplinske obrade postupkom električnog pražnjenja. Optimizacija površinske hrapavosti kao izlazni parametar kao i parametri postupka električnim pražnjenjem uključujući struju, napon i frekvenciju, analizirani su primjenom alata od bakra i kerozena kao dielektrika. U tu svrhu, te kako bi se postigla uspješna statistička analiza eksperimentalnih rezultata, primijenjen je plan pokusa te ne-linearna metoda regresije za procjenu površinske hrapavosti. Zatim su se rezultati analizirali pomoću metode ANOVA te odredili parametri obrade s više učinka na željeni rezultat. Na kraju, dobiven je matematički model za po...

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Section: Effects Of Input Parameters On Surface Roughnessmentioning

confidence: 99%

Section: Effects Of Input Parameters On Surface Roughnessmentioning

confidence: 99%

Modelling and investigating the effect of input parameters on surface roughness in electrical discharge machining of CK45

2016

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“…Ti-6Al-4V alloy has exceptional merits such as high strength-weight ratio, good temperature stability and prominent corrosion resistance, which makes it widely used in aerospace, automobile, chemical and biomedical fields [1,2]. However, it is a hard-to-cut material with its high melting and low thermal conductivity and it not suitable for traditional machining.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on green electrical discharge machining in tap water of Ti–6Al–4V and parameters optimization

Tang

2013

Int J Adv Manuf Technol

102

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Ti-6Al-4V is widely used in the aerospace, automobile, and biomedical fields, but is a difficult-to-machine material. Electrical discharge machining (EDM) is regarded as one of the most effective approaches to machining Ti-6Al-4V alloy, since it is a non-contact electro-thermal machining method, and it is independent from the mechanical properties of the processed material. This paper aims to combine grey relational analysis and Taguchi methods to solve the problem of EDM parameters optimization. From the viewpoint of health and environment, tap water as working fluid has good working environment, since it does not release harmful gas. The process parameters include discharge current, gap voltage, lifting height, negative polarity and pulse duty factor. The electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) as objective parameters are chosen to evaluate the whole machining effects. Experiments were carried out based on Taguchi L 9 orthogonal array and grey relational analysis, and then verified the results through a confirmation experiment. Compared the machining parameters A 1 B 1 C 3 D 2 with A 1 B 2 C 2 D 2 , MRR increased from 1.28 mm 3 /min to 2.38 mm 3 /min, EWR decreased from 0.14 to 0.10 mm 3 /min and SR decreased from Ra 2.37 μm to Ra 1.93 μm. The process parameters sequenced in order of relative importance are: the ratio of pulse width to pulse interval, discharge current, lifting height and gap voltage. The results showed that using tap water machining Ti-6Al-4V material can obtain high MRR, decrease the machining cost and have no harmful to the operators and the environment.

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“…Unsuitable electrical parameters can cause short circuits, low material removal rate (MRR), and high surface roughness (Ra). It can be drawn from the pervious study in electrical discharge machining (EDM) [2][3][4][5]. Therefore, the parameters must be precisely optimized to maximize the process efficiency [6].…”

Section: Introductionmentioning

confidence: 99%

Optimization of cutting conditions of YG15 on rough and finish cutting in WEDM based on statistical analyses

Huang

Ming

Guo

et al. 2013

Int J Adv Manuf Technol

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In this paper, the effects and the optimization of cutting parameters on surface roughness (Ra) and material removal rate (MRR) in the wire electrical discharge machining (WEDM) of high hardness tool steel YG15 are analyzed. In the WEDM process, the key process parameters, such as pulse-on time, pulse-off time, power, cutting feed rate, wire tension, wire speed, and water pressure, are optimized. Experimental data were initially collected based on the Taguchi method of experimental design, which are L 18 2 1 × 3 5 and L 18 2 1 × 3 4 Taguchi standard orthogonal array on rough and finish cutting experiments, respectively. The level of importance of the cutting parameters on the Ra and MRR was determined on both finish and rough cutting by using statistical analyses; average gap voltage is discussed in order to balance cutting efficiency and stability on both finish and rough cutting. In addition, comparative analysis of finish and rough cutting is drawn to analyze the difference between rough cutting and finish cutting. Then, regression models and signal-to-noise ratio are used to obtain the optimum cutting parameter combination. Finally, the results present the optimized MRR and Ra of the rough and finish process, respectively, and confirm the efficiency and abilities of the model.

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Optimization of the EDM parameters on machining Ti–6Al–4V with multiple quality characteristics

Cited by 199 publications

References 15 publications

Modelling and investigating the effect of input parameters on surface roughness in electrical discharge machining of CK45

Modelling and investigating the effect of input parameters on surface roughness in electrical discharge machining of CK45

Experimental study on green electrical discharge machining in tap water of Ti–6Al–4V and parameters optimization

Optimization of cutting conditions of YG15 on rough and finish cutting in WEDM based on statistical analyses

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