Tool Wear Rate Prediction by using Optimization Techniques

Abstract

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

Investigation of electropolishing performance on surface residual stress and morphology of electrical discharge machined maraging steel

“…Electrical Discharge Machining (EDM) is a potential non-conventional thermoelectric machining process used to machine intricate shapes or cavities on these hard (martensitic) and conductive alloys. 2 One major disadvantage associated with EDM is the generation of tensile residual stress on the machined surface due to rapid cooling. 3 Some adverse thermal effects, such as micro-cracks formation, voids, globules, and other defects due to rapid heating and cooling cycles, have also been associated with the EDM, along with poor surface morphology.…”