Study of Tool Wear and Overcut in EDM Process with Rotary Tool and Magnetic Field

Teimouri, Reza; Baseri, Hamid

doi:10.1155/2012/895918

Cited by 55 publications

(33 citation statements)

References 18 publications

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“…The centrifugal force induces due to the rotation of tool electrode prompt removal of accumulated debris from the interelectrode gap. However, some of the debris particles may settle near the cylindrical surface of the machined hole when the debris tends to escape from the interelectrode gap . This eventually leads to the occurrence of spark between the tool electrode and the side surface of the hole.…”

Section: Resultsmentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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This article presents micro electrical discharge machining (μEDM) of carbon fiber‐reinforced plastics (CFRP) with rotating tool electrode and assisting electrode (AE). The experimental investigation majorly focused on establishing the mechanisms of material removal and surface integrity of the machined blind holes. Taguchi and regression analysis were carried out to assess the material removal rate (MRR). Analysis of variance (ANOVA) was applied to understand the significance of input parameters and their contribution toward achieving maximum MRR. The surface integrity of the machined hole and damage modes of composite constituents were also examined through micrographic images. The experiments were carried out varying the voltage, pulse duration, and tool speed at three levels. The investigations showed that μEDM process can be applied for fabricating micro holes in CFRP if assisting electrode (AE) is used to initiate the spark. From the analysis of variance (ANOVA), it was observed that the percentage contribution of voltage, pulse duration, and tool rotational speed on MRR are 75.09, 5.20, and 16.09%, respectively. The optimal condition for the highest MRR was found to be V3/T1/S3 (voltage of 170 V, pulse duration of 10 μs, and tool speed of 800 rpm). The calculated value of MRR (341,264.94 μm3/s) at the optimum level of input parameters was found to be close to the experimental MRR (340,727 μm3/s). The percentage error between the experimental and calculated value of MRR at the optimum level is very low as 0.15%. This indicates that the developed statistical model is quite significant in predicting MRR during μEDM of CFRP. POLYM. COMPOS., 40:4033–4041, 2019. © 2019 Society of Plastics Engineers

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Section: Resultsmentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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“…Step 1: Initial population is generated randomly with in the range as per Table 1 Step Now Consider two random numbers r1 = 0.7332, r2 = 0.4231. Calculate the new value of all parameters candidate as per equation (7). All values of newly calculated parameters should be within the range as per Table 4.…”

Section: Optimization Using Jaya Algorithmmentioning

confidence: 99%

“…Due to this potential difference, there is a series of sparking takes place between two electrodes (one is a workpiece and the other is known as a tool/electrode). Due to this sparking, some material from the surface of the workpiece is melt and flushed away from the machining area [6] and some material from the tool surface also removed [7]. There are many control parameters of electrical discharge machining (EDM).…”

Section: Introductionmentioning

confidence: 99%

Optimization of relative wear ratio during EDM of titanium alloy using advanced techniques

2019

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This study presents the relative wear ratio (RWR) optimization of Titanium alloy 685 for electric discharge machining (EDM). Titanium alloys are widely used in modern industry due to its excellent engineering property like high strength to weight ratio, corrosion resistance. There is difficulty in the machining of titanium alloy with conventional machining processes, hence EDM used to machine titanium alloy. The objective is to maximize the material removal rate (MRR) while the tool wear rate (TWR) should be minimized. The machined surface is an exact replica of the tool face. If TWR increases then the quality of the machined surface deteriorate. A new term introduces a RWR which represents the ratio of MRR to the TWR. The high value of RWR is desired to improve the quality of the machined surface. In this paper RWR is optimized. Response surface model used to develop a regression model of RWR. Optimization of RWR is done by advanced optimization techniques, Jaya Algorithm, teaching-learning-based optimization and response optimizer. Parameters optimization of peak current (Ip), pulse on time (Ton), duty factor (t) and voltage (V) done in this study to maximize RWR.

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“…can be achieved [10]. The tool rotation apart from increasing the MRR reduces the possibility of overcuts during the EDM process [11].…”

Section: Materials Removal Ratementioning

confidence: 99%

Increasing the Performance of EDM Process Using Tool Rotation Methodology for Machining AISI D3 Steel

Dwivedi

Choudhury

2016

Procedia CIRP

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Electric Discharge Machining is one of the most accurate unconventional manufacturing processes used for cutting or creating intricate shapes in very hard or difficult-to-cut, electrically conducting materials. The adoption of tool rotation methodology increases the material removal rate by increasing the spark efficiency and effective debris clearing. The experiments have been performed on AISI-D3 Steel. Results show that the tool rotation phenomenon significantly improves the average MRR and surface finish by 41% and 12% respectively. Moreover, the final surface is more uniform in structure with less number of microcracks and thinner recast layer as compared to the stationary tool EDM.

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Study of Tool Wear and Overcut in EDM Process with Rotary Tool and Magnetic Field

Cited by 55 publications

References 18 publications

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

Optimization of relative wear ratio during EDM of titanium alloy using advanced techniques

Increasing the Performance of EDM Process Using Tool Rotation Methodology for Machining AISI D3 Steel

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