Surface characteristics analysis of dry EDMed AISI D2 steel using modified tool design

Pragadish, N.; Kumar, M. Pradeep

doi:10.1007/s12206-015-0347-z

Cited by 15 publications

(5 citation statements)

References 13 publications

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“…Oxygen gas with 99.99 % purity was used as the dielectric medium and copper rod with 0.43 % impurities was used as the tool. Pragadish et al [8] proposed a special tool design for drilling holes in AISI D2 tool steel. 2 mm diameter hole was drilled on the base of the tool at three pitch circles of diameter 5 mm, 6 mm and 7 mm.…”

Section: Methodsmentioning

confidence: 99%

“…A 10 mm diameter cylindrical copper rod with three uniformly distributed 2 mm diameter holes on its face was used to drill the holes in SS316 L [7]. Pragadish et al [8] conducted the dry EDM machining on AISI D2 tool steel using a tool with specially modified design and observed increased material removal rate (MRR) and surface roughness (SR) as levels of current increases. Zhang et al [9] provided ultrasonic vibration to the work piece and observed the improvement in MRR.…”

Section: Introduction mentioning

confidence: 99%

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Optimum Control Parameters During Machining of LM13 Aluminum Alloy Under Dry Electrical Discharge Machining (EDM) With A Modified Tool Design

Nagarajan

Murugesan

Natarajan

2019

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Dry Electrical Discharge Machining (EDM) is considered as a green manufacturing process in which the liquid dielectric medium is replaced by a high velocity gas, which results improved process stability. A special tool design is adopted to find the optimum control parameters during machining of LM13 Aluminum alloy under dry EDM mode. The drilled and slotted cylindrical copper rod is used as a tool. Discharge current (I), voltage (V), pressure (P) and pulse on time (TON) are considered as varying input process parameters and duty factor and tool rotational speed are chosen at the fixed level. Taguchi L27 orthogonal array is used to design the experiment and the experiments are conducted accordingly. The experimental results are analyzed using Grey Relational Analysis to find the optimal combination of the process parameters. Also, ANOVA test is conducted to ensure the conformity of the simulation results. Pulse on time is found as the most significant parameter which is followed by voltage. Furthermore, the parameters with the highest relational grade (4 A, 200 μs, 60 V and 1.5 kPa) are used in experiment to validate the simulation results. The simulation and experimental results have a good agreement with less than 0.5 % error.

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Section: Methodsmentioning

confidence: 99%

Section: Introduction mentioning

confidence: 99%

Optimum Control Parameters During Machining of LM13 Aluminum Alloy Under Dry Electrical Discharge Machining (EDM) With A Modified Tool Design

Nagarajan

Murugesan

Natarajan

2019

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“…It's evolved if the melted material solidifies through the cooling as well as is deposited upon the finished surface. It's created as a result of the melted material that isn't totally flushed away via the dielectric fluid from the inter-electrode gap (IEG) [35][36]. Such recast hard and brittle layer changes the work material's metallurgical characteristics, which may result in catastrophic failure [37][38].…”

Section: Resultsmentioning

confidence: 99%

Study on Near-Dry EDM Performance Characteristics of MSGNP/Al-7075 Using Air, Argon, Nitrogen, and Freon Dielectric Medium

Abd,

Ali

2023

Adv. Sci. Technol. Res. J.

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The primary aim of the current study is to investigate the influence of input parameters of near dry electric discharge machine (ND-EDM) upon the output performances including the MRR, EWR, SR and WLT for the fabricated new metal matrix composite (MMCs) of aluminum A7075 matrix nanocomposites by adding 8% of Microscopic Slide Glass Nanoparticles (MSGNPs) as reinforcements to improve the metallurgical and mechanical properties of Al-7075/MSGNP composites using stir-casting method. In ND-EDM the dielectric medium plays a significant role in the procedure responses. In the current work, the vegetable oil with gases, such as air, Ar, mix (Ar+N 2 ), and Freon were used as a dielectric media. The obtained results show that the highest MRR achieved when using the vegetable oil + Freon gas, reached 29.425 mm 3 /min, and then 26.943 mm 3 /min when using the vegetable oil + Air as a dielectric. The lowest EWR achieved when employing the vegetable oil + Argon gas, reached 0.120 mm 3 /min, and then 0.175 mm 3 /min. The lowest SR values obtained for all the designed experiments reached 3.287 µm when using Ip (10 A), Ton (1600 µsec), and Ar additive gas, followed by 4.567 µm when adding Freon gases to the dielectric. In the ND-EDM, the average of recast white layer thickness in the case of vegetable oil + air, vegetable oil + Ar, vegetable oil + mix (Ar-N 2 ), and vegetable oil + Freon was 1.505, 1.180, 0.456, and 0 μm, respectively. These unique results can be used to increase the service and fatigue life of parts and machines that are exposed to sudden dynamic mechanical or thermal loads, without the need for additional operations to remove this brittle layer, which causes the failure of these parts with a short service life. The created mathematical models displayed a higher value of R-Square and the adjusted R-square, which manifest a better fit. Normal probability plots of the residuals for MRR, EWR, and SR elucidated an obvious pattern (i.e., the points were stabilized in a straight line) which indicates that every factor affects the mentioned responses and the outcomes of these responses from the regression model (predicted value by factorial) and the true values (from the experiments).

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“…In EDM process, hydrocarbon based dielectric fluids are used which generate harmful elements and it affects environmental and operator safety. To overcome these issues, some of the steps are taken by researchers to adapt EDM process into greened process [1][2][3][4][5]. One of the approaches is dry EDM, which uses gaseous medium as dielectric, but it has limitation of low MRR and debris particle suspended in the gaseous medium.…”

Section: Introductionmentioning

confidence: 99%

Performance Analysis of Vegetable Oil as Dielectric Fluid in Electric Discharge Machining Process of Inconel 800

Singaravel

Shekar

Reddy

et al. 2020

MSF

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Electric discharge machining (EDM) is a spark erosion process widely used to machine difficult-to-cut material by conventional machining method. The major elements of EDM process are work piece, electrode and dielectric fluid. In this work, an attempt is made to investigate vegetable oil as dielectric fluid and their process performance for machining of Inconel 800 in EDM process. The effects of dielectric fluids are investigated with vegetable oils and conventional dielectric fluid namely Sunflower oil and Kerosene respectively. The important input variables considered in this study are pulse on/off time, current and voltage. Three levels of energy setting are employed for machining with selected dielectric fluids. The output parameters are considered tool wear rate (TWR), material removal rate (MRR) and surface roughness (SR). In the present study effect of vegetable oil as dielectric fluid and the results are compared with conventional dielectric fluid. The result revealed that vegetable oils are successfully employed as dielectric fluids and they are having similar dielectric properties and erosion mechanism compared to conventional dielectric fluid. This proposed vegetable oil based dielectric fluids showed higher MRR than conventional dielectric. It shows vegetable oils have similar dielectric properties compared with conventional dielectric and it is possible to replace as dielectric fluid in EDM process.

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Surface characteristics analysis of dry EDMed AISI D2 steel using modified tool design

Cited by 15 publications

References 13 publications

Optimum Control Parameters During Machining of LM13 Aluminum Alloy Under Dry Electrical Discharge Machining (EDM) With A Modified Tool Design

Optimum Control Parameters During Machining of LM13 Aluminum Alloy Under Dry Electrical Discharge Machining (EDM) With A Modified Tool Design

Study on Near-Dry EDM Performance Characteristics of MSGNP/Al-7075 Using Air, Argon, Nitrogen, and Freon Dielectric Medium

Performance Analysis of Vegetable Oil as Dielectric Fluid in Electric Discharge Machining Process of Inconel 800

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