JMMCE  Vol.10 No.11 , September 2011
Parametric Optimization of PMEDM Process using Chromium Powder Mixed Dielectric and Triangular Shape Electrodes
ABSTRACT
In this article, parametric optimization for material removal rate (MRR) and tool wear rate (TWR) study on the powder mixed electrical discharge machining (PMEDM) of EN-8 steel has been carried out. Response surface methodology (RSM) has been used to plan and analyze the experiments. Average current, duty cycle, angle of electrode and concentration of chromium powder added into dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance in terms of MRR and TWR. Experiments have been performed on newly designed experimental setup developed in laboratory. Most important parameters affecting selected performance measures have been identified and effects of their variations have been observed.

Cite this paper
K. Ojha, R. Garg and K. Singh, "Parametric Optimization of PMEDM Process using Chromium Powder Mixed Dielectric and Triangular Shape Electrodes," Journal of Minerals and Materials Characterization and Engineering, Vol. 10 No. 11, 2011, pp. 1087-1102. doi: 10.4236/jmmce.2011.1011083.
References
[1]   W.S. Zhao, Q.G. Meng and Z.L. Wang, “The application of research on powder mixed EDM in rough machining, J. Mater. Process. Technol.129, 30–33, 2002.

[2]   R.K. Garg, K.K. Singh, A. Sachdeva, V.S. Sharma, K. Ojha and S. Singh, “Review of research work in sinking EDM and WEDM on metal matrix composite materials” The International Journal of Advanced Manufacturing Technology, Volume 50, Numbers 5-8, 611-624, DOI: 10.1007/s00170-010-2534-5, 2010.

[3]   Y.F. Tzeng and C.Y. Lee, “Effects of powder characteristics on electro discharge machining efficiency”, Int. J. Adv. Manuf. Technol. 17 (2001)586–592, 2001.

[4]   Y.F. Luo, “The dependence of interspace discharge transitivity upon the gap debris in precision electro-discharge machining”, J. Mater. Process. Technol. 68, 127–131, 1997.

[5]   H. Narumiya, et al., “EDM by powder suspended working fluid”, in: Proceedings of the 9th ISEM, pp. 5–8, 1989.

[6]   N. Mohri, N. Saito and M.A. Higashi, “A new process of finish machining on free surface by EDM methods”, Ann. CIRP 40 (1), 207–210, 1991.

[7]   K.Furutani, A. Saneto, H. Takezawa, N. Mohri and H. Miyake, “Accertation of titanium carbide by electrical discharge machining with powder suspended in working fluid”, Prec. Eng. 25, 138–144, 2001.

[8]   F.Y. Tzeng and Fu Chen, “A simple approach for robust design of high speed electricaldischarge machining technology”, Int. J. Mach. Tool Manuf. 43, 217–227, 2003.

[9]   M. Kunieda and K. Yanatori, “Study on debris movement in EDM gap”, Int. J. Electr. Mach. 2, 43–49, 1997.

[10]   A. Erden and S. Bilgin, “Role of impurities in electric discharge machining”, in: Proceedings of the 21st International Machine Tool Design and Research Conference, Macmillan, London, pp. 345– 350, 1980.

[11]   M.L. Jeswani, “Effects of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining”, Wear 70, 133–139, 1981.

[12]   N. Mohri, et al., “Mirror-like finishing by EDM”, in: Proceedings of the 25th International Symposium on Machine Tool Design and Research, UK, pp. 329–336, 1985.

[13]   H. Kansal, S. Singh and P. Kumar, “State of the art concerning powder mixed EDM”, in: Proceedings of the International Conference on Emerging Technology (ICET-2003) KIIT, Bhubansewar, India, 2003.

[14]   H. K. Kansal, S. Singh and P. Kumar, “Parametric optimization of powder mixed electrical discharge machining by response surface methodology”, Journal of Materials Processing Technology 169, 427–436, 2005.

[15]   N. Mohri, J. Tsukamoto and M. Fujino, “Surface modification by EDM—an innovation in EDM with semi-conductive electrodes”, in: Proceedings of Winter Annual Meet ASME, vol. 34, pp. 21–30, 1988.

[16]   N. Mohri, N. Saito and M.A. Higashi, “A new process of finish machining on free surface by EDM methods”, Ann. CIRP 40 (1), 207–210, 1981.

[17]   B.H. Yan and S.L. Chen, “Effects of dielectric with suspended aluminum powder on EDM”, J. Chin. Soc. Mech. Eng. 14 (3), 307–312, 1993.

[18]   B.H. Yan and S.L. Chen, “Characteristics of SKD11 by complex process of electric discharge machining using liquid suspended with aluminum powder”, J. Jpn. Inst. Light Met. 58 (9), 1067–1072, 1994.

[19]   B.H. Yan and S.L. Chen, “Effect of ultrasonic vibration on electrical discharge machining characteristics of Ti–6Al–4V alloy”, J. Jpn. Inst. Light Met. 44 (5), 281–285, 1994.

[20]   Y. Uno and A. Okada, “Surface generation mechanism in electrical discharge machining with silicon powder mixed fluid”, Int. J. Elec. Mach. 2, 13–18, 1997.

[21]   Y.S. Wong, L.C. Lim, I. Rahuman and W.M. Tee, “Near-mirror-finish phenomenon in EDM using powder-mixed dielectric”, Int. J. Adv. Manuf. Technol. 79, 30–40, 1998.

[22]   B.H. Yan, Y.C. Lin, F.Y. Huang and C.H. Wang, “Surface modification of SKD 61 during EDM with metal powder in the dielectric”, Mater Trans 42(12):2597–2604, 2004.

[23]   K.L. Wu, B.H. Yan, F.Y. Huang and S.C. Chen, “Improvement of surface finish on SKD steel using electro-discharge machining with aluminum and surfactant added dielectric”, Int J Mach Tools Manu 45:1195–1201, 2005.

[24]   K. Kobayashi, T. Magara, Y. Ozaki and T. Yatomi, “The present and future developments of electrical discharge machining”, in: Proceedings of 2nd International Conference on Die and Mould Technology, Singapore, pp. 35–47, 1992.

[25]   Y. Uno, A. Okada, Y. Hayashi and Y. Tabuchi, “Surface integrity in EDM of aluminum bronze wit nickel powder mixed fluid”, J. Jpn. Soc. Elec. Mach. Eng. 32 (70), 24–31 (in Japanese), 1998.

[26]   A. Okada, Y. Uno and K. Hirao, “Formation of hard layer by EDM with carbon powder mixed fluid using titanium electrode”, in: Proceedings of 5th International Conference on Progress of Machining Technology, pp. 464–469, 2000.

[27]   H.M. Chow, B.H. Yan, F.Y. Huang and J.C. Hung, “Study of added powder in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining”, J. Mater. Process. Technol. 101, 95–103, 2000.

[28]   Wang, C.H., Lin, Y.C., Yan, B.H., Huang, F.Y. (2001), “Effect of characteristics of added powder on electrical discharge machining”, J. Jpn. Inst. Light Met., 42(12), 2597-2604.

[29]   K. Furutani and K. Shiraki, “Deposition of lubricant layer during finishing process by electrical discharge machining with molybdenum disulphide powder suspended in working fluid”, in: JSME/ASME International Conference on Materials and Processing, 2002, pp. 468–473, 2002.

[30]   J. Simao, “Work piece surface modification using electrical discharge machining”, Int. J. Mach. Tools Manuf. 43, 121–128, 2003.

[31]   P. Pecas and E.A. Henriques, “Influence of silicon powder mixed dielectric on conventional electrical discharge machining”, Int. J. Mach. Tools Manuf. 43, 1465–1471, 2003.

[32]   C. Cogun, B. Ozerkan and T.Karacay, “An experimental investigation on the effect of powder mixed dielectric on machining performance in electrical discharge machining”, J. Engineering Manufacture, Proc. IMechE Vol. 220 Part B, 1035-1050, 2006.

[33]   H.K. Kansal, S. Singh and P. Kumar, “Effect of Silicon powder mixed EDM on machining rate of AISI D2 die Steel”, Journal of Manufacturing Processes Vol. 9/No. 1, 2007.

[34]   P. Pe?as and E. Henriques, “Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric (PMDEDM)”, Int J Adv Manuf Technol, 37:1120–1132, DOI 10.1007/s00170-007-1061-5, 2008.

[35]   P. Pe?as and E. Henriques, “Electrical discharge machining using simple and powder-mixed dielectric: The effect of the electrode area in the surface roughness and topography”, journal of materials processing technology 200, 250–258, 2008.

[36]   G.S. Prihandana, M. Mahardika, M. Hamdi, Y.S.Wong and Kimiyuki Mitsui, “Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes—Taguchi approach”, International Journal of Machine Tools & Manufacture, 49, 1035–1041, 2009.

[37]   K. Furutani, H. Sato and M. Suzuki, “Influence of electrical conditions on performance of electrical discharge machining with powder suspended in working oil for titanium carbide deposition process”, Int J Adv Manuf Technol, 40:1093–1101, DOI 10.1007/s00170-008-1420-x, 2009.

[38]   K.Y. Kung , J.T. Horng and K.T. Chiang, “Material removal rate and electrode wear ratio study on the powder mixed electrical discharge machining of cobalt-bonded tungsten carbide”, Int J Adv Manuf Technol, 40:95–104 DOI 10.1007/s00170-007-1307-2, 2009.

[39]   Ojha, K., Garg, R.K. and Singh, K.K., (2011) “The Effect of Nickel Micro Powder Suspended Dielectric on EDM Performance Measures of EN-19 Steel”Journal of Engineering and Applied Sciences, Year: 2011, Volume: 6, Issue: 1, Page No.: 27-37, DOI: 10.3923/jeasci.2011.27.37

[40]   K. Ojha and R.K. Garg, “Parametric Optimization of PMEDM Process with Nickel Micro Powder Suspended Dielectric and Varying Triangular Shapes Electrodes on EN-19 Steel”, Journal of Engineering and Applied Sciences, Volume: 6, Issue: 2, Page No.: 152-156, DOI: 10.3923/jeasci.2011.152.156, 2011.

[41]   K. Ojha, R.K. Garg and K.K. Singh, “MRR Improvement in Sinking Electrical Discharge Machining: A Review”, Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No.8, pp.709-739, 2010.

[42]   K. Ojha and R.K. Garg, “A review of tool electrode designs for sinking EDM process”, Published and presented in WSEAS International Conference on Robotics Control and Manufacturing Technology (ROCOM '11), Venice, Italy in March 8-10, 2011.

[43]   K. Ojha, R.K. Garg and K.K. Singh, “Innovative tool electrode designs for sinking EDM process- A review”, Second International Conference on Production & Industrial Engineering (CPIE-2010), NIT-Jalandhar, 3-5th December 2010.

 
 
Top