9 0 obj

Speed (RPM) = (SFM x 3.82) / D; Feed (IPM) = RPM x FPT x Z; SFM (Surface Feet per Minute) = (RPM x D) / 3.82; IPT (Inches per Tooth) = (IPM / RPM) / Z; MRR (Cubic Inches per Minute) = IPM * WOC * DOC; AFPT (@ less than 1/2 dia. “Adeq Precision” measures the signal-to-noise ratio.

Figure 6-8. This layer is caused by the material that was melted during the discharge and then when the discharge current breakdown occurred, a part of the material has resolidified in the crater and surroundings and the rest was flushed away by the dielectric [6]. Rajesha et al. To enter a value, click …

Kumar et al. Orbiting the electrode causes the entire surface of the electrode to be used, instead of the end. The major conclusions drawn from this study are as follows. In addition to this, Figures 4(d), 4(e), and 4(f) show that the normal plot of residuals data is normally distributed and all the experimental results are in the region very near to the predicted values, and, hence, the developed model can be effectively used to predict the surface roughness in EDM of EN 353.

The desirability function involves transformation of each estimated response variable to a desirability value , where .

With the new calculator from Meusburger the cutting data is calculated quickly and easily. Most graphites are easily machined. The interaction effect of pulse on time and pulse off time influences the most.

where and are the weights of electrode material before and after machining, respectively, and is the machining time. S. Rajesha, A. K. Sharma, and P. Kumar, “On electro discharge machining of inconel 718 with hollow tool,”, S. R. Nimbhorkar and B. D. Deshmukh, “Effect of case hardening treatment on the structure and properties of automobile gears,”, A. Bensely, S. Venkatesh, D. Mohan Lal, G. Nagarajan, A. Rajadurai, and J. Boland, “Determination of poisson's ratio of cryogenically treated case carburized steel (En 353) by using ultrasonic technique,” in, S. Murugesan and K. Balamurugan, “Optimization by Grey relational analysis of EDM parameters in machining Al-15% SiC MMC using multihole electrode,”, S. Singh and M. Verma, “A parametric optimization of electric discharge drill machine using taguchi approach,”, F. L. Amorim and W. L. Weingaertner, “Die-sinking electrical discharge machining of a high-strength copper-based alloy for injection molds,”, O. Yilmaz, A. T. Bozdana, M. A. Okka, and I. H. Filiz, “A comparative investigation of the effects of single and multi-channel electrodes in EDM fast hole drilling of aerospace alloys,” in, R. Manikandan and R. Venkatesan, “Optimizing the machining parameters of micro-EDM for Inconel 718,”, N. Sharma, R. Khanna, and R. D. Gupta, “Parametric optimization on WEDM for HSLA by integrated RSM and genetic algorithm,” in, G. Kibria, B. R. Sarkar, B. The ratio of 16.222 indicates an adequate signal. It is important to consider both properties of the workmetal when evaluating EDM performance (figure 6-1).

During EDM processes, a significant amount of workpiece material was found to be transferred from workpiece surface to tool surface and vice versa. A ratio greater than 4 is desirable. Most significant parameters like voltage and current in the optimization of a single quality characteristic are not being significant as in multiple quality characteristics [11]. Under shorter pulse on time, electrical sparks generate smaller craters on the work surface. Figure 3(d) shows the contour plot, while Figures 3(e) and 3(f) show three-dimensional interaction response surfaces for EWR in relation to the input parameters of peak current and pulse off time.

Single-channel electrodes have comparatively better MRR and lower EW during fast hole drilling of Inconel 718 and Ti-6Al-4V with tubular electrodes of brass and copper, while copper electrode undergoes lower wear than brass electrode [7].

No-wear settings do not produce the fastest metal removal rates. Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology, Department of Mechanical Engineering, M. M. University, Mullana, Ambala, Haryana 133203, India. Experiments were conducted on a die sinking EDM machine, model Electronica Xpert 1 CNC as shown in Figure 1(a). › Drilling. Reversing the polarity of sparking alters the material removal phenomenon with an appreciable amount of electrode material depositing on the workpiece surface [26]. <>>> ” of 0.9404. The elements which have a harmful effect on steel and which increase its tendency to cracking are silicon, nickel, sulphur, phosphorus, and carbon [14].

Each application will have different performance requirements that should be considered when selecting an electrode material. �&UR�s١kN7�U��8�r�����җ� r%�Jlq��o�&xbq���=t��ck�aC䲮�x4�/����}{w����U��"�1�J���oB�B��ߠ�U���J(ST�p��L��t4�O{ RMS (root mean square) is obsolete, but still found in some publications.

done the multiobjective optimization with copper electrode and concluded that lower value of parameters reduces the tool wear ratio substantially, while their higher values increase the MRR drastically on AISI tool steel [12]. ” of 0.7301 is in reasonable agreement with the “Adj. Corner wear is also important if the electrode is to be dressed.

6 0 obj Mathematical modeling of process using response surface methodology shows that the developed model can achieve reliable prediction of experimental results within acceptable accuracy [19]. Calculate the metal removal rate for milling cutters and drills.

The results of the quadratic model for EWR in the form of ANOVA are given in Table 5. <> ” of 0.9921 is in reasonable agreement with the “Adj. This is done by measuring the electrode on an optical comparator. It can be extensive to reflect the possible difference in the importance of different responses by giving weights. The procedure followed in this work for simultaneous optimization of the three responses is a modification of the method developed by Derringer and Suich and El-Taweel. Click here for our extensive library of free resources, or contact an applications specialist to discuss the optimal parameters for your milling program. Achieving an efficient MRR is not simply a matter of the right machine settings.

The model value of 43.10 implied that the model is significant for MRR. Figure 6-5.

The desirability of a product characteristic value depends on the lower and upper ranges of product specification. Due to the larger electrode area involved in the cutting process, machining current can be increased to improve metal removal rate. With each discharge, a crater was formed on the machined surface. From the contour plot and response surface, it was observed that minimum EWR 3.5 mm3/min with the low value of peak current at 4 A and pulse off time at 4 μs. The increase in carbon content in the recast layer is intrinsically related to the pyrolysis products that follows the cracking of the dielectric and is very confined to the melted and resolidified work piece material forming the iron carbides. In this case A, B, C, A2, B2, C2, and BC are significant model terms. The process parameters and their levels for the main experiments were decided on the basis of the pilot experiments conducted using one-factor-at-a-time approach as shown in Table 2.

The amount can be calculated by measuring the length of the electrode before the cut and after the cut and subtracting the length after the cut from the original length. International Journal of Manufacturing Engineering. The “Pred.

MRR = w d f r MRR = Material Removal Rate (cu.in./ Min) w = Width of Cut d = Depth of Cut f r = Feed Rate (Dist./ Min) 5

<>>> Calculate the metal removal rate for milling cutters and drills. It was observed that the residuals generally fall on a straight line implying that the errors are normally distributed.

You are currently using the following account for your cart and purchases: These calculations are based upon theoretical values and are only intended for planning purposes. Comparison of orbiting and non-orbiting electrode side wear. The calculation for Material Removal Rate is RDOC x ADOC x Feed Rate. The off-time is set as short as possible to maintain stable machining conditions. The mathematical relationship for correlating the machining rate and the considered process variables is obtained as follows: The fit summary recommended that the quadratic model is statistically significant for analysis of MRR.

The accuracy in calculating MRR is very important. It was observed from the plots that MRR increases (from 14 to 29.03 mm3/min) with increase in peak current and pulse on time. Figure 6-6. The fundamental cause of cracking lies in the existence of the intern stresses which are created at the time of the machining operation.

Amorim and Weingaertner concluded that the best results of MRR and surface texture for duty factor of 0.5 were obtained with tungsten-copper electrodes, no matter the machining conditions while machining copper-beryllium ASTM C17200 alloy [6]. Figures 3(a), 3(b), and 3(c) show the effects of different input factors (pulse on time, pulse off time, and peak current) on the response parameter EWR. correctly setting up your tooling and material allows you to maximise machining quality, as well as product quality. 11 0 obj 3 Table 8 gives the optimal input process parametric setting for multiresponse optimization. The amount of taper is determined by measuring the bottom of the cut and subtracting it from the top of the cut. Review articles are excluded from this waiver policy. The sharper the angle, the more sparks are generated in this area and the more heat buildup.

Discharge current, pulse on time and pulse off time, had a significant influence on the machining characteristics such as MRR, EWR, and overcut while machining Inconel 718 [8] and on gap current while machining high strength low alloy steel (HSLA), respectively [9].

Corner Wear = Apparent Corner Wear + End Wear. The apparent corner wear is the length lost at the 90° angle.

<> Nodules may form on the end of the electrode and distort the shape of the electrode (figure 6-7).

endobj Actual results will vary. where is volume of material removed and is the machining time. The small particle size and high strength give this grade the ability to hold and maintain intricate detail. Milling Formulas. ���p̵��(�@��ufAvh�k1)a�9N� 4 0 obj In this study, an effort has been made to model the empirical relationship between machining parameters by using response surface methodology. However, speed is not usually the only consideration when cutting cavities.

Finer surface finishes can be obtained with an orbiting electrode. As these particles are carried along by the dielectric they can mechanically abrade the sides of the electrode. Below are variable abbreviations and formulas for many common milling operations. Although it is possible to obtain no-wear conditions with graphite from any of the five classifications, not all electrode/workmetal combinations can be put in a no-wear condition.

Measurements would be taken before and after the cut.

where is the number of responses . The “Pred. The weights of the electrodes were measured using a balance. The steel is being divided into low carbon, medium carbon, and high carbon steel on the basis of carbon content.

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