Optimization of EDM process parameters for machining SS310

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p-ISSN: 2395-0072

Optimization of EDM process parameters for machining SS310

A. Chandrakanth1 , Dr. Md. Aleem pasha2, T.N. Aditya3 K. Gurubrahmam4 1,3,4 Assistant Professor, Dept. of Mech. Engg., CBIT, Hyderabad, Telangana, India 2Associate Professor, Dept. of Mech. Engg., CBIT, Hyderabad, Telangana, India ***

Abstract The Electrical discharge machining is a widely used Precision manufacturing process. The EDM process involves a controlled erosion of electrically conductive materials by initiation of repetitive spark discharge between electrode tool and work piece, separated by a small gap of called as spark gap. In the current work, optimization of various process parameters to increase Materialremovalrate and to decrease tool wear rate is done using Taguchi’s method. Coppers is used as tool materials and SS310 is used as work piece material. The process parameters selectedaredischarge current and spark gap. The output characteristics measured are Material Removal rate and tool wear rate. A full factorial design of experiment is used to find the influence of process parameters on Metal Removal Rate and tool wear rate. The main effects and interaction effects are plotted. From the experiments it was found that discharge current is the most influencing factors on MRR and TWR using copper as the electrode.

Key Words: EDM: Electron Discharge Machining; MRR: Material Removal Rate; SS: Stainless steel; TWR: Tool Wear Rate

1. INTRODUCTION

Electrical discharge machining (EDM) has long been the answer for high accuracy, demanding machining applicationswhereconventionalmetalremovalisdifficultor impossible. Known by many othernames,including spark machining, arc machining and (inaccurately) burning, the EDM process is conceptually very simple: an electrical currentpassbetweenanelectrodeandaworkpiecewhich areseparatedbyadielectricliquid.Thedielectricfluidacts asanelectricalinsulatorunlessenoughvoltageisappliedto bringittoitsionizationpoint,whenitbecomesanelectrical conductor. Theresultingspark dischargeerodesthework piecetoformadesiredfinalshape.

EDMhastheabilitytomachinecomplexshapesinveryhard metals.ThemostcommonuseofEDMisinmachiningdies, toolsandmouldsmadeofhardenedsteel,tungstencarbide, high speed steel and other work piece materials that are difficult to machine by "traditional" methods. Because of technicaladvancesinelectrodewear,accuraciesandspeed, EDMhasreplacedmanyofthetraditionalprocesses.Another factor contributing to the growing use of EDM is the expansionoftheworkenvelope,particularlywhenitcomes toheightsandtapers.

1.1 EDM MACHINE

ThemachiningiscarriedoutonElectronicaC 425EDM machine.Themachinessetupanditsspecificationsaregiven below

Fig -1:ElectronicaC-425EDMmachine

Table 1: SpecificationsoftheEDMmachine

Worktank 600x400x280mm

Worktablesize 400x250mm Tabletraverse 250x170mmMax

Maxworkpieceweight 100kg height 160m

Zaxistraverse 150mm

Leastcounterofvernier 0005mm

Shutheight 260mm

Throat 320mm

No.ofpowersettings 99x9

Powersupply 3phase,415vAC 50Hz

Machinedimensions 1130x1040x1800mm

NoofTslots 3 Maxworkingcurrent 22Amps

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International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

2. METHODOLOGY

Inthepresentwork,optimizationoftheinputparametersfor various output parameters are done using Design of Experiments. Two input parameters at three levels are considered for the experiment. The input process parametersandtheirlevelsareshowninthetablebelow

Table 2: SelectedInputparameterswithlevels

Control parameters Level1 Level 2 Level 3

Discharge current (Amp) 4 8 12 Spark gap (mm) 0.05 0.1 0.15

Theexperimentsareconductedusingfullfactorialdesign by selecting L9 orthogonal array. The experiments are designed using Taguchi’s method. The experiments were conductedondiesinkelectricdischargemachineasshownin Fig.1whichconsistaworktable,aservocontrolsystemanda dielectricsupplysystem.Themachinehascurrentsettingsup to22A.TheexperimentsareconductedonAISI310material withdimensionsare100mmx25mmx5mm.Workpiece material properties are: Hardness (HRC)= 43 45, density (g/cm3)= 8.16, Ultimate tensile strength (Kg/mm2) =85, Elongation % =3. The tool material used is copper with density896gm/cm3andthermalconductivityof386w/mk andthemachiningisdonewithstraight polarity.Spooilis used as the dielectric fluid and the experiments were performed for a particular set of input parameters. The numberofexperimentsandinputlevelsaredecidedbasedon thedesignofexperimentsandtheinputparametersandtheir levels.TheMRRandTWRarecalculatedusingdigitalbalance of accuracy 1mg and the machining time is using digital watch of accuracy 1 microsecond. The weight of the workpieceandtoolbeforemachiningisrecordedusingthe digital balance. The total machining time is also recorded usingadigitalwatch.Theinputparametersandtheirlevels areshowninTable 3.

Table 3: Processparametersselectedforexperimentation

The machining samples after the experimentation are markedforvariousprocessparameters.The samplesafter themachiningprocessareshowninthefig.2

Fig 2:Samplesaftertheexperimentation

3. RESULTS AND DISCUSIONS

Theoutputvaluesarecalculatedbymeasuringtheweightof the workpiece and tool after the machining process. The differenceintheweightofthesamplesisusedtocalculate MRRandTWR.Thecalculatedoutputparametersareshown inthetable 4below.

Table 4: outputresponsesrecordedafterexperimentation

Experi ment No.

Discharg e current (Amp)

Spark gap (mm)

MRR mm3/min TWR mm3/min 1 4 0.05 9.677 4.650 2 4 0.10 10.193 5.580 3 4 0.15 12.534 5.391 4 8 0.05 4.313 2.391 5 8 0.10 5.298 3.597 6 8 0.15 7.373 3.256 7 12 0.05 3.124 1.584 8 12 0.10 1.801 1.291 9 12 0.15 1.481 0.859

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Fig 3:Maineffectformeans(MRR)

Fig 6:InteractioneffectplotforS/Nratio(MRR)

Table 5:ResponseTableofMeansforMRR

Level Amp mm 1 10.801 5.705 2 5.661 5.764 3 2.135 7.129 Delta 8.666 1.425 Rank 1 2

Table 6:ResponseTableforSignaltoNoiseRatiosLarger isbetterforMRR

Fig -4:Interactionplotformeans(MRR)

Level Amp mm 1 20.614 14.102 2 14.844 13.253 3 6.139 14.242 Delta 14.476 0.989 Rank 1 2

Table 7:ANOVAresultsforMRR

Source DF SS MS F P Amp 2 113.9518 56.9759 30.983 0.001 mm 6 11.0335 1.8389 Total 8 124.9854

Table 8:VarianceComponents

Source VarComp. %of Total StDev Amp 18.379 90.90 4.287 mm 1.839 9.10 1.356 Total 20.218 4.496

Fig 5:maineffectplotforS/Nratio(MRR)

Table 9:ExpectedMeanSquares

1 Amp 1.00(2)+ 3.00(1) 2 mm 1.00(2)

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International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

Thefollowingfiguresshowthemaineffectandinteraction effectplotsforToolwearrate

Fig -7:Maineffectformeans(TWR)

Fig 10:InteractioneffectplotforS/Nratio(TWR)

Table 10:ResponseTableofMeansforTWR

Level Amp mm 1 5.207 2.875 2 3.081 3.489 3 1.245 3.169 Delta 3.962 0.614 Rank 1 2

Table 11:ResponseTableforSignaltoNoiseRatios SmallerisbetterforTWR

Level Amp mm 1 14.305 8.305 2 9.648 9.423 3 1.631 7.856 Delta 12.674 1.568 Rank 1 2

Fig 8:Interactionplotformeans(TWR)

Table 12:ANOVAresultsforMRR

Source DF SS MS F P Amp 2 23.5919 11.7959 46.494 0.000 mm 6 1.5222 0.2537 Total 8 25.1141

Table 13:VarianceComponents

Source VarComp. %of Total StDev Amp 3.847 93.81 1.961 mm 0.254 6.19 0.504 Total 4.101 2.025

Table 14:ExpectedMeanSquares

Fig 9:MaineffectplotforS/Nratio(TWR)

1 Amp 1.00(2)+ 3.00(1) 2 mm 1.00(2)

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International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

4. CONCLUSION

From the experimental results, the main effect plots and interactionplotsaregeneratedforMaterialremovalrateand Tool wear rate. The S/N ratio is also calculated by considering maximum is better for Material removal rate andminimumisbetterforToolwearrate.FromTable 6it can be concluded that discharge current is the most influentialfactorforMaterialremovalrateandhencemore dischargecurrentisrecommended.FromTable 11,itcanbe concluded that discharge current is most influential parameter for Tool wear rate. The experimental investigationscanbecarriedoutwithmorenumberofinput processparameters

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