Comparative study for material removal rate, surface finish and electrode wear rate on die sinking edm
The electrical discharge machining (EDM) is one of non conventional machining process where the erosion of the work piece take place based on the the1mal energy between the electrode and the work piece. Two different work piece materials were machined using die sinking EDM to study the characteri...
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| Format: | Thesis |
| Language: | English English |
| Published: |
2013
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| Subjects: | |
| Online Access: | http://eprints.utem.edu.my/id/eprint/14708/1/Comparative%20Study%20For%20Material%20Removal%20Rate%20Surface%20Finish%20And%20Eletrode%20Wear%20Rate%20On%20Die%20Sinking%20EDM%2024pages.pdf http://eprints.utem.edu.my/id/eprint/14708/2/Comparative%20study%20for%20material%20removal%20rate%2C%20surface%20finish%20and%20electrode%20wear%20rate%20on%20die%20sinking%20edm.pdf |
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| Summary: | The electrical discharge machining (EDM) is one of non conventional machining process
where the erosion of the work piece take place based on the the1mal energy between the
electrode and the work piece. Two different work piece materials were machined using die
sinking EDM to study the characteristics of each material using copper electrode. Two
different work piece materials were used, aluminum and copper and the dimension for each is
100 mm length, 50mm width and 6mm thick. The Sodick CNC EDM die sink will be used as
the main equipment in this project. To get the best result, the selections of parameters play a
main role in producing good surface finish quality, high removal rate (MRR) and less
electrode wear ratio (EWR). High electtode wear ratio (EWR) and the lower material removal
rate is some of the problems in EDM machine that will decrease machining productivity.
There are four different pulse cunent that will be tested (8 , 12, 16 and 20 ampere) with four
pulse on time in micro second (50, 100, 150, and 200) and the reference voltage and pulse on
time are kept constant 22 Volt. There are sixteen engrave will be formed in each sample.
Dielectric fluid is used is kerosene and the polarity or machining type is positive. At the end of
this study the optimal performance parameters will be defined and determining which mate1ial
gives highest mate1ial removal rate, less surface finish as well as the conditions that give less
tool wear rate (TWR). The result obtained indicating that the material removal rate MRR and
TWR are increased with the increase of cun-ent. This is because the higher cun-ent means
higher and stronger spark that generates or melt more material from the work piece. The result
shows that pulse duration has a little effect on the MRR. But regarding the tool wear ration
TWR the results show a decrease of the TWR along with the increase of pulse duration this is
because of the presence of carbon layer that precipitated on the surface of the electrode and the
thickness of this layer increased with the increase of pulse duration and in tum decrease the
TWR. Regarding the comparative study, the result showed that aluminum has higher MRR
compared with copper, this is due to the fact that aluminum has lower melting point compared
with copper. And regarding the TWR, the results showed that the copper has little amount of
tool wear when machined using copper electrode, this is because the copper has higher
thennal conductivity compared to aluminum who has higher TWR when machined using same
copper electrode. The higher the1mal conductivity means more the1mal energy this work piece
can can-y and also means more facilitating the the1mal energy will be diffused which maintain
the tool wear. |
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