A Review on Optimization of Process Parameters for Improving Performance in Electrical Discharge Machining
The correct selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM). It is a capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries. From the point of view of industrial applications, SS 410 is a very important material and that’s why for the purpose of experimentation SS 410 with copper electrode and EDM oil as dielectric has been used In the present work. I will take input parameter discharge current, pulse on time and pulse off time. Design of Experiment (DOE) with full factorial design has been explored to produce 27 specimens on SS 410 by edm operation. MRR will be calculated from MRR equation and software available for it and then compare it. Collected data related to surface roughness have been utilized for optimization.
Statistical Modeling and Optimization of Process Parameters in Electro-Discharge Machining of Cobalt-Bonded Tungsten Carbide Composite (WC/6%Co)
Abstract In this paper, attempts have been made to model and optimize process parameters in Electro-Discharge Machining (EDM) of tungsten carbide-cobalt composite (Iso grade: K10) using cylindrical copper tool electrodes in planing machining mode based on statistical techniques. Four independent input parameters, viz., discharge current (A: Amp), pulse-on time (B: μs), duty cycle (C: %), and gap voltage (D: Volt) were selected to assess the EDM process performance in terms of material removal rate (MRR: mm3/min), tool wear rate (TWR: mm3/min), and average surface roughness (Ra: μm). Response surface methodology (RSM), employing a rotatable central composite design scheme, has been used to plan and analyze the experiments. For each process response, a suitable second order regression equation was obtained applying analysis of variance (ANOVA) and student t-test procedure to check modeling goodness of fit and select proper forms of influentially significant process variables (main, two-way interaction, and pure quadratic terms) within 90% of confidence interval (p-value≤0.1) It has been mainly revealed that all the responses are affected by the rate and extent of discharge energy but in a controversial manner. The MRR increases by selecting both higher discharge current and duty cycle which means providing greater amounts of discharge energy inside gap region. The TWR can be diminished applying longer pulse on-times with lower current intensities while smoother work surfaces are attainable with small pulse durations while allotting relatively higher levels to discharge currents to assure more effective discharges as well as better plasma flushing efficiency. Having established the process response models, a multi-objective optimization technique based on the use of desirability function (DF) concept has been applied to the response regression equations to simultaneously find a set of optimal input parameters yielding the highest accessible MRR along with the lowest possible TWR and Ra within the process inputs domain. The obtained predicted optimal results were also verified experimentally and the values of confirmation errors were computed, all found to be satisfactory, being less than 10%. The outcomes of present research prove the feasibility and effectiveness of adopted approach as it can provide a useful platform to model and multi-criteria optimize MRR, Ra, and TWR during EDMing WC/6%Co material.
Effect of WC particle size on the microstructure, mechanical properties and fracture behavior of WC--(W, Ti, Ta) C--6wt% Co cemented carbides
Abstract This study deals with the microstructure and mechanical properties of WC–(W, Ti, Ta) C–9 vol.% Co cemented carbides fabricated by conventional sintering. The conventional WC particles of 4 μm size and ultrafine particles of 0.2 μm were introduced in the system with varying ratio. The ratios of conventional WC particles to ultrafine WC particles were 2:1, 1:1, and 1:2. The microstructures of sintered WC–(W, Ti, Ta) C–9 vol.% Co cemented carbides were sensitively dependent on the ratio of conventional WC particles to ultrafine WC particles. The rim phase increased with the increase in the amount of ultrafine particles. Hardness of WC–(W, Ti, Ta) C–9 vol.% Co cemented carbide increased with increase in the amount of rim phase and decrease in the average grain size of WC particles. The bending strength showed the similar trend of the hardness. The fracture morphologies are reported. The fracture behavior changed from mixed mode to transgranular fracture mode, when the ratio of conventional WC particles to ultrafine WC particles was changed from 2:1 to 1:2.