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![Table 1 : Physical properties of aluminium alloy LM6 [14]](profile/Raja-Izamshah/publication/301683724/figure/tbl1/AS:614213848412166@1523451401354/Physical-properties-of-aluminium-alloy-LM6-14_Q320.jpg)
This paper investigates the performance of copper, copper tungsten, graphite and brass electrode on machining characteristics of aluminium alloy LM6 (Al-Sil2) in the electrical discharge machine (EDM) die sinking. The relationship between the machining parameters such as peak current, voltage, pulse-on time, and pulse-off time on machining characte...
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... As supported by previous research [19], the density and viscosity of the dielectric fluid may affect the MRR. RBD palm oil had a higher viscosity and flash point than kerosene, resulting in more sparking [33][34][35][36][37]. At the same parameter settings of Ip=12A and ton=150µs, the improvement was approximately 567.49%. ...
The type of dielectric fluid is the most significant component that might affect the machining performance of EDM such as material removal, tool wear, and electrode surface roughness. However, the most serious of these issues is the inability to comply with health and environmental rules when the conventional dielectric was harmful to the surrounding ecosystem. One approach to ensure the long-term sustainability of EDM is to use vegetable oil as the dielectric fluid as it is environmentally friendly and biodegradable. To satisfy industrial objectives, the machining industry must ensure that the maximum material removal rate (MRR) can be achieved. This paper investigated the effect of kerosene and refined, bleached, and deodorised (RBD) palm oil as dielectric fluids with different peak currents (6, 9, and 12A) and pulse duration (50, 100 and 150µs) settings on MRR of Titanium alloy. Kerosene was used as a benchmark to compare the performance of the EDM process. The implementation of RBD palm oil recorded the lowest MRR at the lowest peak current of 6A with the lowest pulse duration of 50µs, which is 1.1260mm3/min. In contrast, the highest MRR with a value of 12.1323mm3/min was recorded at the highest peak current of 12A with a pulse duration of 150µs. Overall, RBD palm oil shows an excellent MRR performance for substituting hydrocarbon or mineral oil as a dielectric fluid in EDM applications, improving cost, time, and production efficiency.
... As the kerosene was generated at lower EWR compared to RBD palm oil, it might due to the protective effect of the deposited carbon layer on the copper electrode. Thus, in terms of EWR, it can be concluded that RBD palm oil exhibited a pattern similar to kerosene, despite significant differences at higher peak current [29][30][31][32][33][34]. This proves that palm oil can be used in the EDM machining process. ...
... The figures depict the surface morphology based on the lowest and highest EWR when kerosene and RBD palm oil were used as dielectric fluids. As a result, the lower EWR has shown the distribution of the deposited material is wider and more compared to the highest EWR resulted [13,[29][30][31][32][33][34][35]. In contrast to lower EWR, higher EWR indicates a wider shape of material deposited upon that copper electrode surface despite the higher peak current applied, which resulted in more material deposited melting. ...
Electrical Discharge Machining (EDM) is a widely utilized commercial method for generating a variety of forms of materials that are used as the fundamental material in a wide range of industries. Vegetable oil as the dielectric fluid is one technique for assuring EDM's long-term viability because it is ecologically benign and biodegradable. This article presents experimental investigations on the influence of electrical discharge machining (EDM) input parameters on electrode wear rate (EWR) while using EDM oil and vegetable oil as dielectric fluid. Kerosene which is known as conventional oil for EDM has been used as a benchmark to compare the feasibility of the EDM process by using a different type of dielectric fluid which is RBD palm oil. Peak currents (Ip) in the 6 to 12A range and pulse durations (ton) in the 50 to 150 µs range were chosen as the major factors for this study to improve the efficiency of EDM operation. Scanning electron microscopy (SEM) was used to observe the morphology surface characteristics of the copper electrode and the migration of workpiece material elements to the tool electrode. The EWR increases with increasing peak current, although it is inversely related to pulse duration. The lowest EWR for kerosene and RBD palm oil is 0.0416mm3/min and 0.0480mm3/min, respectively, at the same IP=6A and ton=150µs. Simultaneously, the highest EWR for both kerosene and RBD palm oil was at the same IP=12A and ton=50µs, which is 0.1725mm3/min and 0.2425mm3/min, respectively.
... Extremely delicate materials and sections can be machined without the risk of deformation because they are not in direct physical contact with one another. The addition of powder to the EDM process's dielectric fluid is a recent improvement [4,5]. PMEDM and AEDM are other names for this process [6]. ...
... Machining stability improves EDM outputs like MRR, TWR, and SR [5]. The wider discharge gap, which helps to keep the flushing of debris on a more even keel, is what makes stability possible. ...
Powder-mixed electrical discharge machining (PMEDM) is the process of enhancing the output of the machined surface by combining dielectric fluid with various types of powders. This process is quickly gaining acceptance in the electrical discharge machining (EDM) sector. The purpose of this study is to determine whether a dielectric fluid containing tantalum carbide (TaC) powder can improve material removal rate (MRR) also lessen tool wear rate (TWR) during the subsequent EDM machining of stainless steel material. During the machining, the material removal rates, tool wear rate, and mathematical models of two different EDM mediums were examined. For the machining procedure, kerosene dielectric fluid containing TaC powder at a concentration of 25.0 g/L was used. The machining input variables were used peak current, pulse on time, and pulse off time. We determined how these variables affected the MRR and TWR of the copper-based EDMed electrode tools. During electrical discharge machining, the MRR for stainless steel (SUS 304) was increased by MRRPMEDM by 4.3 to 5.3% and TWRpEDM was reduced by 37.9% when TaC powder additive was used. Optimized results also show that TWR and maximum MRR can be achieved at 81.98% and 13.779mm 3 /min respectively with 83.50% desirability whenever the pulse on-time and pulse off-time are 6.20 µs and 6.50 µs respectively. The models are reliable and can be used to forecast the machining responses within the experimental region, it can be said. The MRR and TWR model for EDM with TaC powder additive (MRRPMEDM) identifies current as the most significant factor, followed by pulse on time and pulse off-time.
... Spark discharges melt and evaporate a minor amount of workpiece material across a gap (spark gap) between the tool and the workpiece [5]. During a machining process, spark discharges always happen at the highest electrical potential point, which floats around the machining gap at random [6,16]. Steel with extremely high hardness and unusual metals such as Inconel, Hastelloy, Kovar, titanium, tungsten, silicon, nickel, cobalt, carbide, and so on. ...
Conventional surface modification methods, such as ion insertion and laser surface melting, have recently seen growing importance in the innovative usage of the electrical discharge machining process (EDM) as a competitive substitute. Surface composition and properties are affected by several factors, including erosion of work materials and tool materials during the process, as well as the formation of plasma channels from the vaporized materials. This indicates that, under certain machining conditions, deliberate materials transfer may be possible using either a composite electrode by scattering metallic powders in a dielectric or a combination of the two. However, the traditional electrode has not been very successful in the surface modification process. Although it has been considered, expanding research into the use of powder additives through EDM techniques to enhance the level of surface modification is lacking. In addition, the pulse interval is not included in the existing works that examine the impact of technique parameters on surface modification. Because of this, a thorough optimization of the process has not been possible to characterize the connection between the independent variables under control and the machining parameters. To take full advantage of the benefits offered by EDM, it is necessary to learn more about the missing links between the process and its desired outcomes, such as whether or not surface alloying of metallic materials using EDM is feasible and what controls should be used for the various variables involved. The purpose of this study was to assess the efficiency of EDM-based surface alloying of stainless steel using Tantalum Carbide (TaC) powder as an additive by measuring the resulting surfaces' roughness (SR). It was found that RaPMEDM 11 μm recorded at current 5A and on-time 6.30 μs, off-time 7.00 μswith powder concentration 25g/L. The RaPMEDM is easy to predict by controlling factor current (A) and on-time (B). At the higher current of 7.25A, RaPMEDM showed to decrease slightly. This result justifies TaC powder starts to control and modify the surface of stainless steel at a high factor current. In the case of without additives RaEDM, at maximum current 5 A, on-time 6.26 μs, and off-time 7 μs, RaEDM recorded 7 μm. Although it provided the highest Ra compared to RaPMEDM.
... Ali et al. investigated the effects of copper, coppertungsten, graphite and brass tools on the MRR, TWR and Ra in the parameters range of discharge current (2-30 A), pulse on time (100-400 µs), pulse off time (1-9 µs) and reference voltage (21-30 V) during EDM of aluminium LM6 alloy. The authors mentioned that the thermal conductivity and melting point of the tool material affect the performance results [17]. Kakkar et al. examined discharge current (7,9,11 A), reference voltage (30,40,50 V) and pulse on time (50,100,150 µs) variable parameters on the MRR, TWR and Ra in machining Al-SiC metal matrix composite with EDM. ...
Aluminum alloys are widely preferred in various fields such as aerospace, ship and automotive due to their lightness and relevant production cost. In this study, electro discharge technique was used in the processing of aluminum 5083 alloy (Al5083) produced by powder metallurgy method. The surface quality resulting from the experiments was investigated in terms of Ra, Rz and Rsm. Experimental studies were carried out according to Taguchi L9 orthogonal experimental design, using three different levels of discharge current, pulse on time and pulse off time parameters. As the discharge current increased, Ra and Rz increased, Rsm first decreased and then increased. As the pulse on time increased, Ra and Rz first increased and then decreased, and Rsm increased. When the pulse off time increased, Ra and Rz decreased and Rsm increased. As a result of the analysis of variance (ANOVA) performed to determine the effect rates of the variable parameters on the surface quality, the order of importance of the parameters was found to be discharge current, pulse off time and pulse on time. The effect of discharge current, which is the most effective parameter according to ANOVA, on Ra, Rz and Rsm was calculated as respectively 70.87%, 70.41% and 36.34%. Microscopic images taken from the tool (copper) and workpiece surface show that the craters and peaks formed by the spark effect are formed on both material surfaces.
... The graphical representation (Figure 4a) shows that among the other electrode materials, graphite (electrode material: level 1) yields highest MRR. This is due the fact that graphite has greater thermal conductivity, density, and hardness values compared to brass and copper, and resulted in the highest spark during the EDM machining of HcHcr tool steel [63]. Peak current trends show negligible impact (i.e., 7.04% contribution) compared to the rest of the variables (see percent contribution in Table 8). ...
... Note that the eigenvalues of the first principal components are greater than 1, and the second principal component (PC2) was found close to unity and the resulted explained variation of the corresponding principal components is less than 50% of the total explained variation (100%) (refer to Table 11). Since there are no standard procedures defined for the resulted eigenvalues greater than one for one response and close to unity for the other response (i.e., principal components) and less explained variations, authors followed the said literature [61][62][63][64][65][66]. Table 11 presents the eigenvectors calculated based on the eigenvalues. ...
Industries demand stringent requirements towards economical machining without hindering the surface quality while cutting high carbon high chromium (HcHcr) steel. Electrical discharge machining (EDM) of HcHcr steel aims at reducing machining cost (i.e., maximize material removal rate (MRR) and minimize tool wear rate (TWR)) with good surface quality (i.e., minimize surface roughness (SR)). A comparative study was carried out on EDM of HcHcr D2 steel (DIN EN ISO 4957) by applying Taguchi L18 experimental design considering different electrode materials (copper, graphite, and brass), dielectric fluids (distilled water and kerosene), peak current, and pulse-on-time. The process performances were analyzed with respect to material removal rate, surface roughness, and tool wear rate. Pareto analysis of variance was employed to estimate the significance of the process variables and their optimal levels for achieving lower SR and TWR and higher MRR. Hybrid Taguchi-CRITIC-Utility and Taguchi-PCA-Utility methods were implemented to determine the optimal EDM parameters. Higher MRR of 0.0632 g/min and lower SR of 1.68 µm and TWR of 0.012 g/min was attained by graphite electrode in presence of distilled water as dielectric fluid compared to the brass and copper. Additionally, a metallographic analysis was carried out to study the surface integrity on the machined surfaces. Micrographic analysis of the optimal conditions showed lower surface roughness and fewer imperfections (lesser impression, waviness surface , and micro-cracks) compared to worst conditions.
... By considering of electrode material, Md Ali et al., [56] stated that Brass electrode shows low ability to withstand of spark energy that produces highest EWR and it is also reveal that thermal conductivity and melting point of electrode materials influence the output quality of material characteristics of workpiece. Meanwhile, Mahmud and Yahya [57] concluded that machining microdimples using flyback power supply gave higher MRR as well as provide improvement in its consistency of material removed per minutes. ...
Magnesium alloys have been widely used in biodegradable applications due to it tends to corrode inside the human body and combined with its initial mechanical property. Current research revealed that the structural stability of the implant is disturbed and lost rapidly due to the increased rate of degradation of magnesium inside the human body. Because of that, non-traditional machining method such as electrical discharge machining (EDM) die sinking process is implemented to create an intricate form with a high tolerance of magnesium alloy. The advantages of EDM are that it allows a versatile adaption of implant behaviour in machining complex 3D structures along with high corrosion resistant properties of electrochemical surface treatment. Various material types with different parameters are investigated to determine the influence of input process parameters on the energy saving, and machining characteristics included surface roughness, material removal rate, and tool wear rate. In addition to improving the machining performance especially in energy-saving, input on the machining parameter needs to be considered due to interaction with added conductive particles which would affect the size of discharge energy. The objective of this paper is to summarize the findings in research of EDM's energy-saving and machining characteristics on magnesium alloy and to explore challenging issues that need to be resolved for future references and recommendations.
... This caused larger volumes of melted materials and craters are created. Md Ali et al., [6] studied the performance of different electrode use. They selected copper, copper tungsten, graphite and brass electrode for machining aluminium alloy LM6 (Al-Sil2). ...
Currently, the industry generally uses electrical discharge machining (EDM) with kerosene facing problems in terms of processing efficiency, perilous environment, and low quality of the machined surface. In this paper, water-in-oil (W/O) emulsion dielectric is introduced as an alternative for this drawback. Kerosene has low properties especially thermal conductivity, viscosity and, higher heat capacity. Vegetable oil such as canola oil can be selected as an alternative dielectric fluid. This work has measured the properties of canola oil including thermal conductivity, heat capacity and viscosity for possible use as a dielectric fluid. The result shows that the emulsion of canola oil has the best combination at 35wt% of Tween20 with heat applied.
... By considering of electrode material, Md Ali et al., [56] stated that Brass electrode shows low ability to withstand of spark energy that produces highest EWR and it is also reveal that thermal conductivity and melting point of electrode materials influence the output quality of material characteristics of workpiece. Meanwhile, Mahmud and Yahya [57] concluded that machining microdimples using flyback power supply gave higher MRR as well as provide improvement in its consistency of material removed per minutes. ...
... Many researchers well reported the optimization of a single performance characteristics or single response [4][5][6][7][8][9]. However, doing a multi-answer optimization is hard, more complicated and challenging because of its complexity. ...
Various parameters affecting the drying process of an apple were optimized by adopting the Taguchi experimental design technique (TEDT). Such a technique reduces the number of experiments while maintaining excellent accuracy and treating the measured values and their dispersion for the process parameters including the drying air temperature, the relative humidity, the velocity and the sample shape factor. The goal is to optimize the drying time as well as the internal mechanical stress as the average moisture content in the dried sample reaches value resultant in water activity of 90%. The optimized combination of conditions (parameters levels) were found to be in ranges: temperature [60, 70 °C], velocity [1.25, 2 m/s], relative humidity [5, 15%] and a sample shape ratio of 0.5 for an estimated average time 242.75 min and an estimated mechanical stress 5.46e7 MPa . A confirmation test by COMSOL using the optimized conditions gives excellent agreement with the estimated values emerging from the TEDT optimization and resulting in around four hours of drying time
