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Cite this Article Mukesh Regmi, Anil Pol, Sachin Kulkarni, Multi Response
Optimisation of Die Sinker EDM for Alsic Composite. International Journal
of Mechanical Engineering and Technology, 7(3), 2016, pp. 6377.
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1. INTRODUCTION
Parts manufactured by casting, forming, and various shaping processes often require
further operations before they are ready for use or assembly. So a proper machining
need to be done which involves the removal of some material from the work piece
(machining allowance) in order to produce a specific geometry at a certain degree of
accuracy and surface quality in a cheap cost.
In modern machining practice, harder, stronger, and tougher materials that are
more difficult to cut are frequently used. More attention is, therefore, directed toward
machining processes where the mechanical properties of the work piece material are
not imposing any limits on the material removal process. In this regard, the
nonconventional machining techniques like Electric Discharge Machining (EDM)
came into practice [1].
Electric Discharge Machining (EDM), sometimes colloquially also referred to
as spark machining, spark eroding, burning, die sinking or wire erosion, is an electrothermal 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. Material is removed from the work piece by a series of rapidly recurring
current discharges between two electrodes which are separated by
a dielectric liquid and subject to an electric voltage.
As shown in the Fig. (1) DC power supply provides power to the configuration i.e.
tool and the workpiece. The tool is generally given negative polarity and workpiece is
given positive polarity. When the voltage across the gap becomes sufficiently high it
discharges through the gap in the form of the spark producing very high temperature
and thus melting and eroding the material.
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2. LITERATURE REVIEW
P. Janmanee et al. [3] evaluated the performance of different electrode materials like
graphite, copper-graphite and copper-tungsten in EDM of tungsten carbide. The
important parameters were discharge current, pulse on time, pulse off time, opencircuit voltage and electrode polarity. Their investigation concluded that MRR
increases with the discharge current intensity and graphite electrode gives the most
MRR but it gives high electrode wear ratio.
B.Mohan et al. [4] had studied EDM of AlSiC composites with 20-25 vol. % SiC
taking the following like Current, electrode material polarity, pulse duration and
rotation of electrode on MRR, TWR, and SR. It was observed that the increase in
volume percentage of SiC has resulted in decrease in MRR, SR and increase in EWR
and the increase in rotational speed of the tube electrode has produced higher MRR,
EWR and better SR.
Harish K.Garg et al. [5] studied about the machining of the hybrid Aluminium Metal
Matrix composite (Al/SiC/Gr and Al/Si10Mg/Fly ash/Gr). They investigated about
the problems encountered during machining of hybrid MMCs and concluded that
machining of Al/SiC-MMC is one of the major problem, which resist its wide
spread application in industry and the problems faced were rapid TWR, irregular
MRR, requirement of large pulse current values, difficult to cut very complex and
complicated shape or geometrical profile etc.
S.L.Chen et al. [6] studied about various parameters of EDM like electrode material,
pulse duration, discharge current and polarity using two materials namely silicon
carbide and tungsten carbide as work piece and copper and copper tungsten as a tool
material. They concluded that MRR is directly proportional to current and pulse
duration, Electrode wear increased up to 80 s then started decreasing with increase
in pulse duration. They came into conclusion that Copper is better than copper
tungsten as an electrode material due to homogeneous wear ratio.
Selection of process variables such as Intensity of current, Pulse on time & Pulse off
time in Die-Sink-EDM for machining of Al/SiC Metal Matrix Composite.
To investigate the Effect of different tool Electrodes such as brass & CuW on MRR
and TWR
To develop an empirical model for Intensity of current, Pulse on time & Pulse off
time for machining of Al/Sic Metal Matrix Composite using RSM.
To verify the lack of fit of the proposed model using analysis of variance
(ANOVA).
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b) Workpiece material
The workpiece material chosen was aluminium silicon carbide (AlSiC) metal matrix
composite produced with stir casting method consisting of aluminum matrix with 3%
silicon carbide particles. It has high thermal conductivity (180200 W/m K), and
its thermal
expansion can
be
adjusted
to
match
other
materials,
e.g. silicon and gallium arsenide chips and various ceramics. It is chiefly used
in microelectronics as substrate for power
semiconductor
devices and
high
density multi-chip modules, where it aids with removal of waste heat.
c) Response Surface Methodology
Response surface methodology (RSM) is a collection of mathematical and statistical
techniques that are useful for modeling and analysis of problems in which output or
response is influenced by several variables and the goal of RSM is to find the
correlation between the response and the variables. It is used in the development of an
adequate functional relationship between a response of interest, y, and a number of
associated control (or input) variables denoted by x1, x2, xk.
Suppose X1 and X2 are the factors or parameters of interest of the process and Yi
is the maximum yield of the process then the yield is a function of levels of X 1 and X2
i.e.
Yi= f (X1, X2) + ei
(1)
where ei represents the noise or error observed in the response Yi. If we denote
the expected response by
E (Yi) = f (X1, X2) =
(2)
(3)
Design
Factors
Replicates
Total runs
20
Base blocks
Base runs
20
Cube points
Total
blocks
Axial
Points
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-1
+1
Pulse on time
20
40
60
Current
e) Macine used
The experimentation was conducted using EDM, model SAVITA 4631l (Die sinking
type) having following specificationsTable 3 Machine Specifications
S.N.
TYPES
Unit
46311
mm3
600*370*250
Table size
mm2
350*200
X-Axis Travel
mm
200
Y-Axis Travel
mm
120
Z-Axis Travel
mm
150
mm
140
kg
50
kg.
150
Lt.
100
10
Machine Weight
kg
450
11
Gross weight
kg
600
12
Day Light
mm
410
13
Throat
mm
250
14
Overall Dimensions
m3
0.8*0.8*1.8
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4. EXPERIMENTATION
a) Experimental Procedure
Experiment was conducted with negative polarity of electrode. The electrode brass
was taken. The diameter of electrode is measured with a micrometer. It was made
sure its dimension is according to specification.
An initial mass is measured with precision balance. The electrode mass value and the
work piece mass value were jotted.
The work material (Aluminium Silicon Carbide) was mounted on the T-slot table and
positioned at the desired place and clamped. The electrode was clamped on the tool
holder, and its alignment was checked.
The parameters of the experiment were set regarding Table (3.1) and Table (3.2).
The time was set as 2 minutes for the machining of all work materials. Finally,
switches ON for operating the desire discharge current values.
After machining operation, the electrode was taken out and weighed again on
weighing balance. Also the mass value of work piece was taken after machining.
The same experiment was repeated with copper tungsten electrode. This experiment
is done 20 times for each electrode. The data was fed to the MINITAB where
calculation and analysis of results is done.
(1)
Where,
(1.2)
Where,
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9 10 11 12 13 14 15 16 17 18 19 20
9 10 11 12 13 14 15 16 17 18 19 20
The MRR and TWR values were calculated for both the copper tungsten and brass
tool experimental run and then plotted on the graph with their corresponding values.
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Coeff.
SE Coeff.
T test
P value
-0.276914
0.102577
-2.700
0.022 *
0.037469
0.036520
1.026
0.329
Ton
0.007907
0.002650
2.984
0.014 *
Toff
0.032999
0.015603
2.115
0.061 *
I* I
-0.001465
0.002939
-0.499
0.629
Ton *Ton
-0.000076
0.000029
-2.600
0.027 *
Toff *Toff
-0.001665
0.001306
-1.275
0.231
I*Ton
0.000081
0.000172
0.472
0.647
I*Toff
-0.000098
0.001149
-0.085
0.934
Ton*Toff
-0.000233
0.000115
-2.029
0.070 *
R-Sq(adj) = 83.95%
From the ANOVA table, the main effects of pulse on time and pulse off time can
be deduced as having significant effect. Thus, the final model correlating Material
Removal Rate with cutting parameters is found as follows:
The effectiveness of the model is checked by using the R 2 value i.e. 0.91 which
is very close to 1 and hence the model is found to be very effective. The validity of
the model is reconsidered with the adjusted correlation coefficient i.e. R 2 (adj.)value
= 0.83, which is a measure of the variability of the observed output and can be
explained by the factors along their factor interactions.
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Current
Pulse on time
0.18
0.16
0.14
Mean
0.12
0.10
4
6
Pulse off time
20
40
60
0.18
0.16
0.14
0.12
0.10
The graph shows that increase in the value of current leads to the significant
increase in MRR. This increase of MRR with current is due to the fact that with the
increase in amount of pulse current generates strong spark which creates higher
temperature, due to which more material is melted and eroded from the workpiece [8].
The graph reveals that on increasing the pulse on time, MRR goes on increasing
up to half the way and it goes on decreasing from 40s to 60s. This event has been
attributed to the increase of input energy in high pulse on time duration, which results
in more chopping on the gap between workpiece and tool electrode, creating a short
circuit which decreases the efficiency of electrical spark erosion. In other words short
pulse on time duration causes less vaporization, whereas long pulse on time duration
causes the plasma channel to expand, resulting in less energy density on workpiece,
which is insufficient to melt and/or vaporize the workpiece material [9].
It is also evident that on increasing the pulse off time, MRR goes on increasing
from 2s to 5s. It is because of correct flushing of the debris with sufficient pulse off
time duration; otherwise the debris could make the spark contaminated and unstable,
thus decreasing MRR [9]. However it goes on decreasing from 5s to 8s. This is
because when pulse off increases, there will be an undesirable heat loss which does
not contribute to MRR. This will lead to drop in the temperature of the workpiece
before the next spark starts and therefore MRR decreases [8].
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Coeff.
SE Coeff.
T test
P value
-0.053817
0.016443
-3.273
0.008 *
0.018497
0.005854
3.160
0.010 *
Ton
-0.000539
0.000425
-1.269
0.233
Toff
0.007907
0.002501
3.161
0.010 *
I* I
-0.000916
0.000471
-1.944
0.081 *
Ton *Ton
0.000014
0.000005
3.018
0.013 *
Toff *Toff
-0.000813
0.000209
-3.881
0.003 *
I*Ton
-0.000113
0.000028
-4.084
0.002 *
I*Toff
0.000081
0.000184
0.441
0.668
Ton*Toff
-0.000004
0.000018
-0.215
0.834
S = 0.00312493,
R-Sq = 90.68% ,
R-Sq(pred) = 36.49%,
R-Sq(adj) = 82.29%
Table shows that effect of current and pulse off time terms are found to be
statistically significant while except current*pulse on time all interaction terms
contributed less significantly to the TWR at 90 % confidence level. Thus, the final
model correlating TWR with machining parameters is found as follows:
R2 value of 90.68 % indicates that, the variation in the response can be predicted
90 % correctly by using the above model developed for 90 % confidence interval.
Main Effects Plot for TWR
Data Means
Current
Pulse on time
0.020
0.015
Mean
0.010
4
6
Pulse off time
20
40
60
0.020
0.015
0.010
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Coeff.
SE Coeff.
T test
P value
0.1333896
0.072320
1.851
0.094 *
0.009196
0.025748
0.357
0.728
Ton
-0.000118
0.001868
-0.063
0.951
Toff
-0.032872
0.011000
-2.988
0.014 *
I* I
-0.002344
0.002072
-1.131
0.284
Ton *Ton
-0.000028
0.000021
-1.355
0.205
Toff *Toff
0.000250
0.000921
0.271
0.792
I*Ton
0.000208
0.000121
1.711
0.118
I*Toff
0.006094
0.000810
7.524
0.000 *
Ton*Toff
0.000119
0.000081
1.466
0.173
S=0.0137441,
R-Sq=95.57%, R-Sq(pred)=65.23%,
R-Sq(adj)=91.58%
From ANOVA Table below, the main effects of pulse off time can be deduced as
having significant effect. Thus, the final model correlating MRR with cutting
parameters is found as follows:
From Table, it is evident that the model is adequate at 90% confidence level. The
effectiveness of the model is checked by using the R 2 value i.e. 0.95 which is very
close to 1 and hence the model is found to be very effective. The validity of the model
is reconsidered with the adjusted correlation coefficient i.e. R 2 (adj.)value = 0.91,
which is a measure of the variability of the observed output and can be explained by
the factors along their factor interactions.
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0.18
Pulse on time
0.16
0.14
Mean
0.12
0.10
4
20
40
60
0.18
0.16
0.14
0.12
0.10
2
The graph shows that MRR increase proportionately with the current. The graph
reveals that on increasing the pulse on time, MRR goes on increasing up to half the
way and it goes on decreasing. This event has been attributed to the increase of the
discharge energy of the plasma channel leading to the formation of a bigger molten
material crater on the workpiece resulting higher MRR. But consequently by the
dispersion of more heat from the spark stricken position and increasing the amount of
heat transferred, the plasma channels efficiency in removing molten material from
the crater at the end decreases [10]. It is also evident that on increasing the pulse off
time, MRR goes on increasing from. It is because of correct flushing of the debris
with sufficient pulse off time duration; which would otherwise make the spark
contaminated and unstable, thus decreasing MRR [9].
c) Results of TWR with Brass
Table 7 Estimated Regression Coefficients for TWR
Terms
Coeff.
SE Coeff.
T test
P value
C
I
Ton
Toff
I* I
Ton *Ton
0.053029
-0.021541
0.000019
0.015188
0.002042
0.00002
0.016021
0.005704
0.000414
0.002437
0.000459
0.000005
3.310
-3.377
0.046
6.233
4.448
0.513
0.008 *
0.004 *
0.964
0.000 *
0.001 *
0.619
Toff *Toff
I*Ton
I*Toff
Ton*Toff
-0.001729
-0.000041
0.000898
-0.000002
0.000204
0.000027
0.000179
0.000018
-8.474
-1.513
5.004
-0.136
0.000 *
0.161
0.001 *
0.895
S = 0.00304471,
R-Sq = 97.25%,
R-Sq(pred) = 79.50%,
R-Sq(adj) = 94.77%
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From the ANOVA table above, effect of current and pulse off time terms are
found to be statistically significant. Thus, the final model correlating TWR with
machining parameters is found as follows:
(6)
R value of 97.25 % indicates that, the variation in the response can be predicted
97 % correctly by using the above model developed for 90 % confidence interval.
2
0.06
Pulse on time
0.05
Mean
0.04
0.03
4
20
40
60
0.06
0.05
0.04
0.03
2
The graph shows that at the current of 4A, TWR is found to be minimum. Graph
depicted the linear increase in the value of TWR with current. The reason is that, at
low current a small quantity of heat is generated and a substantial portion of it is
absorbed by the surroundings, as a result, the amount of utilized energy in melting and
vaporizing the electrodes is not so intense. But by the increase in pulse current a
substantial quantity of heat will be transferred into the electrodes. Furthermore as the
pulse current increases, the discharge strikes the surface of the electrode more
intensely and creates an impact force on the molten material in the crater and causes
more molten material to be ejected out of the electrode [10].
The graph reveals that on increasing the pulse on time, TWR increases half the
way and goes on decreasing. Moreover longer pulse on time can provide enough time
for heavier positive ions attacking the cathode workpiece and hence removing more
material from the work than the tool [11].
It is also evident that on increasing the pulse off time, TWR goes on increasing
from 2s to 5s and almost showed a constant TWR after that. This is due to the fact
that the long pulse duration provides a better heat removal around the surface of brass
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6. CONCLUSION
Summarizing the main features the following conclusions can be drawn1. The predicted machining performance values match the experimental values
reasonably well; with R2 of 91.55% and 90.68% respectively for MRR and TWR
using copper tungsten as tool electrode and 95.57% and 97.25% respectively for
the MRR and TWR using brass as the tool electrode.
2. It has been observed that MRR as well as TWR goes on increasing with the
current.
3. It was observed that MRR goes on increasing with pulse on time till halfway and
goes on decreasing for both electrodes while TWR follows the same trend for
brass tool but TWR goes on decreasing with pulse on time for copper tungsten.
4. It has also been seen that MRR as well as TWR goes on increasing half the way
and decreases with pulse off time using copper tungsten as an electrode but for the
brass electrode MRR kept on increasing all the way with pulse off time and TWR
kept on increasing half the way and almost remained constant after that.
5. It has been observed that TWR goes on increasing with the current and MRR goes
on increasing with pulse on time till halfway and goes on decreasing.
6. Copper Tungsten electrode gave the higher MRR than the brass electrode. Not
only that TWR was also very less in CuW as compared to the brass electrode with
the same values of the machining conditions. So it is concluded that copper
tungsten is better than brass electrode.
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