Optimizing electric discharge machining parameters for tungsten-carbide utilizing thermo-mathematical modelling

Singh, Harminder; Shukla, Dinesh Kumar

doi:10.1016/j.ijthermalsci.2012.03.017

Cited by 35 publications

(15 citation statements)

References 38 publications

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“…Indeed, a duty cycle of 0.12 is obtained from longer pulse-off than pulse-on time; therefore, when the tool is made anode, a longer time is needed to restore the initial flushing conditions for efficient processing; in this sense, longer pulseoff times are suggested. Furthermore, extending the pulse-on time results in uncontrolled expansion of the discharge channel, with consequent reduction of fused metal and energy density within the channel [18]; extended pulse-on time is suggested instead to maximize MRR when the tool is made cathode, in agreement with other findings in the literature [9], as the highest percentage of discharge energy applies to the work-piece. As TWR follows a similar trend, further conclusions must be drawn considering the wear ratio, whose trend is shown in Fig.…”

Section: Effect Of Duty Cyclesupporting

confidence: 80%

“…A one-factor-at-a-time approach is common feature, anyway. For instance, Singh and Shukla [9] firstly changed the duration of discharge, then the current intensity for given base levels of the other parameters. Lee and Li [10] conducted a first test to select the electrode, then a second test for polarity; voltage has been finally selected in a third test aiming to maximize MRR and minimizing TWR.…”

Section: Introductionmentioning

confidence: 99%

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Electrical Discharge Machining of René 108 DS Nickel Superalloy for Aerospace Turbine Blades

et al. 2015

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Manufacturing industries aim for high quality production with decreased cost and time. To this purpose, optimization of the processing parameters is required, in order to reduce the machining time and match the quality standards. This study has been conducted to electrical discharge machining on Renè 108 DS. In the process, the electrode material is crucial for metal removal and tool wear, whose optimization usually leads to conflicting goals. Therefore, two electrode materials, graphite (Poco EDM-3) and copper-infiltrated-graphite (Poco EDM-C3) have been tested in a factorial plan including current, voltage, duty cycle and electrode polarity. The process is discussed in terms of material removal rate, tool wear rate, wear ratio and final surface roughness of the work-piece.

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Section: Effect Of Duty Cyclesupporting

confidence: 80%

Section: Introductionmentioning

confidence: 99%

Electrical Discharge Machining of René 108 DS Nickel Superalloy for Aerospace Turbine Blades

et al. 2015

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“…Shabgard et al [19] presented that the fraction of heat going into the cathode was a function of pulse current and pulse duration. Harminder [24,25] performed an experiment to study the fraction of energy transferred to the workpiece utilizing heat transfer equations. And it is clearly shown that energy distribution varies with variation of either pulse duration or pulse current.…”

Section: Femmentioning

confidence: 99%

“…Joshi and Pande [17] introduced three energy zones, and each zone has a different distribution factor. Harminder [24,25] performed an experiment to study the fraction of energy transferred to the workpiece. In order to increase the accuracy of the theoretical thermal models used for the prediction of machining characteristics (MRR, Ra), value of f c needs to be varied with variation of input parameters (I, T on ).…”

Section: Heat Distributionmentioning

confidence: 99%

A hybrid process model for EDM based on finite-element method and Gaussian process regression

Ming

Zhang

et al. 2014

Int J Adv Manuf Technol

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This paper proposed a hybrid intelligent process model, based on finite-element method (FEM) and Gaussian process regression (GPR), for electrical discharge machining (EDM) process. A model of single-spark EDM process has been constructed based on FEM method, considering the latent heat, variable heat distribution coefficient of cathode (f c ), and plasma flushing efficiency (PFE), to predict material removal rate (MRR) and surface roughness (Ra). This model was validated using reported analytical and experimental results. Then, a GPR model was proposed to establish relationship between input process parameters (pulse current, pulse duration, and discharge voltage) and the process responses (MRR and Ra) for EDM process. The GPR model was trained, tested, and tuned using the

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“…This appeared to be the main reason for the incompatibilities between numerical results and real-time EDM process [9]. Later on, DiBitonto [10] assumed that only a small part of discharge energy (F c =18 %) is transferred to cathode and the remaining energy is either transferred to anode or is dissipated to dielectric fluid.…”

Section: Introductionmentioning

confidence: 99%

An inverse heat conduction method to determine the energy transferred to the workpiece in EDM process

Shabgard

Akhbari

2015

Int J Adv Manuf Technol

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In this paper, an inverse heat conduction method is applied to estimate the amount of the energy (F c ) transferred to the workpiece during electric discharge machining (EDM) process. Embedded thermocouples which were connected to a four channel data logger were utilized to measure the temperature of a specific location on a rectangular workpiece during the EDM process. After temperature measurements were done, the 2-D heat conduction model of the workpiece and the Levenberg-Marquardt (LM) scheme were used to determine the energy transferred to the workpiece. This inverse procedure facilitates the determination of the heat energy at discharge-workpiece interface in EDM processes, which yet is a challenge for existing numerical models. The obtained results showed that the energy transferred to the workpiece varies with the discharge current and pulse duration from 5 % up to 45 %, which shows that the value of F c is a function of discharge current and pulse duration and that the fixed value of energy assumed in majority of the previous researches is not in accordance with real EDM conditions. Furthermore, the effects of machining parameters such as discharge current and pulse duration on F c were studied. It was evident that the F c has a direct but non-linear relationship with both discharge current and pulse duration, while discharge current has a higher impact on F c .

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Optimizing electric discharge machining parameters for tungsten-carbide utilizing thermo-mathematical modelling

Cited by 35 publications

References 38 publications

Electrical Discharge Machining of René 108 DS Nickel Superalloy for Aerospace Turbine Blades

Electrical Discharge Machining of René 108 DS Nickel Superalloy for Aerospace Turbine Blades

A hybrid process model for EDM based on finite-element method and Gaussian process regression

An inverse heat conduction method to determine the energy transferred to the workpiece in EDM process

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