Electric discharge machining with analysis of variance
Transcript of Electric discharge machining with analysis of variance
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Experimental investigation on influence of process parameters &
magnetic field on machining characteristics of Untreated High
Speed Steel (M2) in EDM
PRESENTATION BYA.ADITYA REDDY
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ABSTRACT : Electric Discharge Machining (EDM) is one of the most accurate
non -traditional machining process available for creating tiny apertures, complex shapes etc.
The objective of EDM is to get high MRR along with achieving reasonably good surface quality of machined component.
It has important machining parameters like discharge current (Ip), Voltage(v), pulse on time (Ton), pulse off time (Toff), magnetic field strength(Mf) and work time (Tw) are considered for investigation.
The effects of machining parameters such as metal removal rate (MRR), Tool wear rate (TWR), surface roughness (SR) are investigated with and without magnetic field for Untreated High Speed Steel (M2).
In this experiment,copper tool is used to machine the work piece.
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EDM : It is an electro thermal non traditional machining process, where
electrical energy is used to generate electrical spark and material removal mainly occurs due to thermal energy of the spark.
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WORKING PRINCIPLE :Whenever sparking takes place between two electrical contacts, a small
amount of material is removed simply as “controlled erosion through a series of electric sparks”
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EXPERIMENTATION : Tool and workpiece are connected to the DC power
supply. A dielectric fluid(EDM 30) is circulated to the gap between tool and work piece.
when the current is passed across the electrodes a narrow column of spark is generated between the tool and workpiece.
optimum gap is to be maintained between the tool and workpiece.
Kinetic energy of electrons converted into heat energy from which material is removed.
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WORKPIECE :Untreated High Speed Steel (M2) It is Tungsten Molybdenum High Speed Steel Composition (C-0.85, Mn-0.28, Si-0.3, Cr- 4.15, W-6.15, Mo- 5, V-1.85) Density : 8138Kg/m3
Specific Gravity : 8.14 Modulus Of Elasticity : 30 x 106 psi (207GPA)
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TOOl :Copper Electrode (Circular cross-section) 99% pure Copper Good thermal conductivity Corrosion resistance Good Machinability High strength
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MAGNET : Material : Ferro Ceramic Alloy Type : Ring Dimensions : OD 90mm x ID
36mm x 15mm Thk Field Strength : 0.9 Tesla
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DI ELECTRIC FLUID :Dielectric Fluid : EDM-30Properties : Allowable Burn Rate: 150 Amp Specific Gravity: 0.80 @ 25° F Viscosity: 36 SSU @ 100°F (38°C) Flash Point: 200° F Dielectric Strength: 45KVfunctions of dielectric : cools down the tool & work piece Flushes away the debris Localizes the spark energy into a small cross-sectional area
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OPTIMIZATION :
For the optimization of Machining parametersAnalysis Of Variance (ANOVA)Response Surface Methodology (RSM)Techniques are used
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READINGS OF MACHINING :Current(amp)
Voltage(v)
Ton(ms)
Toff(ms)
Time(min)
MRR(mm3/min)
TWR(gr/min)
SR(µm)
15 40 7 7 10.246 20.6279 0.0875 5.56
15 50 8 8 14.436 15.8324 0.0388 4.92
15 60 8 8 13.60367 16.9818 0.0412 2.56
15 70 9 9 17.51667 10.9434 0.0832 5.24
20 70 7 8 14.22367 16.0688 0.1261 5
20 80 8 7 12.15433 22.8486 0.1383 4.039
20 40 9 10 15.638 15.7941 0.0501 6.08
20 60 10 9 9.671167 27.1905 0.0695 4.7
25 80 7 7 12.03417 18.7881 0.4005 5.52
25 70 8 9 11.08383 19.623 0.0505 5.4
25 60 9 7 9.516167 28.4081 0.0117 3.529
25 80 10 8 13.997 18.6115 0.1281 3.919
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GRAPHS RELATED TO MRR :
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GRAPHS RELATED TO TWR :
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GRAPHS RELATED TO Ra :
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MULTI RESPONSE OPTIMIZATION :
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READINGS OF MACHINING : WITH MAGNETCurrent
(amp)Voltage(v)
Ton(ms)
Toff(ms)
Time(min)
MRR(mm3/min)
TWR(gr/min)
SR(µm)
15 40 7 7 7.35033 25.9123 0.1067 5.64
15 50 8 8 10.3648 16.7162 0.1297 5.039
15 60 8 8 12.4782 25.4068 0.0718 5.52
15 70 9 9 14.891 11.8003 0.0376 3.54
20 70 7 8 12.2988 12.2891 0.0638 2.429
20 80 8 7 10.272 17.2262 0.1309 3.219
20 40 9 10 13.5345 20.4278 0.0911 4.359
20 60 10 9 11.3367 12.5734 0.0494 2.429
25 80 7 7 12.6843 29.4502 0.1325 5.8
25 70 8 9 12.359 13.2236 0.0453 5.96
25 60 9 7 7.08167 27.2424 0.0791 4.419
25 80 10 8 14.6775 21.0137 0.0611 5.72
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GRAPHS RELATED TO MRR :
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GRAPHS RELATED TO TWR :
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GRAPHS RELATED TO Ra :
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MULTI RESPONSE OPTIMIZATION :
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