Modeling of Material Removal on Machining of Ti-6Al-4V through EDM using Copper Tungsten Electrode and Positive Polarity
This paper deals optimized model to investigate the
effects of peak current, pulse on time and pulse off time in EDM performance on material removal rate of titanium alloy utilizing copper tungsten as electrode and positive polarity of the electrode. The experiments are carried out on Ti6Al4V. Experiments were
conducted by varying the peak current, pulse on time and pulse off time. A mathematical model is developed to correlate the influences of these variables and material removal rate of workpiece. Design of
experiments (DOE) method and response surface methodology
(RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through
analysis of variance (ANOVA). The obtained results evidence that as
the material removal rate increases as peak current and pulse on time
increases. The effect of pulse off time on MRR changes with peak ampere. The optimum machining conditions in favor of material removal rate are verified and compared. The optimum machining
conditions in favor of material removal rate are estimated and verified with proposed optimized results. It is observed that the developed model is within the limits of the agreeable error (about
4%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.
[1] M. Armendia, A. Garay, L.M. Iriarte and P.J. Arrazola, "Comparison of
the machinabilities of Ti6Al4V and TIMETAL® 54M using uncoated WC-Co tools," J. Mater. Process. Tecnol., vol. 210, pp. 197-203, 2010.
[2] G. L├╝tjering, J.C. Williams, Titanium. Springer, 2007.
[3] E. Ezugwu, Z. Wang, "Titanium alloys and their machinabilityÔÇöa
review," J. Mater. Process. Technol. vol. 68, pp. 262-274, 1997.
[4] M. Rahman, Y.S. Wong, A.R. Zareena, "Machinability of titanium alloys," JSME Int. J. Series C46, pp. 107-115, 2003.
[5] S. Prabhu and B.K. Vinayagam, "Effect of graphite electrode material
on EDM of AISI D2 tool steel with multiwall carbon nanotube using
regression analysis. Int. J. Eng. Studies., vol. 1, no 2, pp. 93-104, 2009.
[6] K.H. Ho and S.T. Newman, "State of the art electrical discharge machining (EDM)," Int. J. Machine Tools Manufac., vol. 43, pp. 1287-
1300, 2003.
[7] K. Ponappa, S. Aravindan, P.V. Rao, J. Ramkumar and M. Gupta, "The
effect of process parameters on machining of magnesium nano alumina composites through EDM," Int. J. Adv. Manufac. Technol., vol 46,
pp. 1035-1042, 2010.
[8] B.H. Yan, H.C. Tsai, and F.Y. Huang, "The effect in EDM of a dielectric
of a urea solution in water on modifying the surface of titanium," Int. J.
Machine Tools Manufac., vol 45, pp. 194-200, 2005.
[9] C.L. Lin, J.L. Lin and T.C. Ko, "Optimisation of the EDM process based
on the orthogonal array with fuzzy logic and grey relational analysis method," Inter. J. Adv. Manuf. Technol., vol. 19, pp. 271-277, 2002.
[10] A. Hascalik and U. Caydas, "Electrical discharge machining of titanium
alloy (Ti-6Al-4V)," Appl. Surf. Sci., vol. 253, pp. 9007-9016, 2007.
[11] S.S. Habib, "Study of the parameters in electrical discharge machining
through response surface methodology approach," Appl. Math. Modelling, vol. 33, pp. 4397-4407, 2009.
[12] P. Fonda, Z. Wang, K. Yamazaki and Y. Akutsu, "A fundamental study
on Ti-6Al-4V-s thermal and electrical properties and their relation to EDM productivity," J. Mater. Process. Technol., vol. 202, pp. 583-589,
2008.
[13] M.K. Pradhan and C.K. Biswas, "Modelling of machining parameters
for MRR in EDM using response surface methodology," National
Conference on Mechanism Science and Technology: From Theory to
Application. National Institute of Technology, Hamirpur: 13-14
November, 2008.
[14] I. Puertas and C.J. Luis, "A study on the machining parameters optimisation of electrical discharge machining," J. Mater. Process. Technol., vol. 143-144, pp. 521-526, 2003.
[15] K.L Wu, B.H. Yan, J.W. Lee and C.G. Ding, "Study on the characteristics of electrical discharge machining using dielectric with surfactant," J. Mater. Process. Technol., vol. 209, pp. 3783-3789, 2009.
[16] R.C. Drof and A. Kusiak, "Handbook of design manufacturing and
automation," Singapore: A Wiley-Interscience Publication, 1994.
[17] S.H. Lee and X.P. Li, "Study of the effect of machining parameters on
the machining characteristics in electrical discharge machining of tungsten carbide," J. Mater. Process. Technol., vol. 115, pp. 344-358,2001.
[18] M. Kunieda, B. Lauwers, K.P. Rajurkar and B.M. Schumacher,
"Advancing EDM through fundamental insight into the process. CIRP Technol. vol. 54, no. 2, pp. 64-87, 2005.
[19] J.Y. Kao and Y.S. Tarng, "A neutral-network approach for the on-line
monitoring of the electrical discharge machining process," J. Mater.
Process. Technol. vol. 69, pp. 112-119, 1997.
[20] H.K. Kansal, S. Singh and P. Kumar, "Numerical simulation of powder
mixed electric discharge machining (PMEDM) using finite element
method," Math. Comp. Modell., vol. 47, pp. 1217-1237, 2008.
[1] M. Armendia, A. Garay, L.M. Iriarte and P.J. Arrazola, "Comparison of
the machinabilities of Ti6Al4V and TIMETAL® 54M using uncoated WC-Co tools," J. Mater. Process. Tecnol., vol. 210, pp. 197-203, 2010.
[2] G. L├╝tjering, J.C. Williams, Titanium. Springer, 2007.
[3] E. Ezugwu, Z. Wang, "Titanium alloys and their machinabilityÔÇöa
review," J. Mater. Process. Technol. vol. 68, pp. 262-274, 1997.
[4] M. Rahman, Y.S. Wong, A.R. Zareena, "Machinability of titanium alloys," JSME Int. J. Series C46, pp. 107-115, 2003.
[5] S. Prabhu and B.K. Vinayagam, "Effect of graphite electrode material
on EDM of AISI D2 tool steel with multiwall carbon nanotube using
regression analysis. Int. J. Eng. Studies., vol. 1, no 2, pp. 93-104, 2009.
[6] K.H. Ho and S.T. Newman, "State of the art electrical discharge machining (EDM)," Int. J. Machine Tools Manufac., vol. 43, pp. 1287-
1300, 2003.
[7] K. Ponappa, S. Aravindan, P.V. Rao, J. Ramkumar and M. Gupta, "The
effect of process parameters on machining of magnesium nano alumina composites through EDM," Int. J. Adv. Manufac. Technol., vol 46,
pp. 1035-1042, 2010.
[8] B.H. Yan, H.C. Tsai, and F.Y. Huang, "The effect in EDM of a dielectric
of a urea solution in water on modifying the surface of titanium," Int. J.
Machine Tools Manufac., vol 45, pp. 194-200, 2005.
[9] C.L. Lin, J.L. Lin and T.C. Ko, "Optimisation of the EDM process based
on the orthogonal array with fuzzy logic and grey relational analysis method," Inter. J. Adv. Manuf. Technol., vol. 19, pp. 271-277, 2002.
[10] A. Hascalik and U. Caydas, "Electrical discharge machining of titanium
alloy (Ti-6Al-4V)," Appl. Surf. Sci., vol. 253, pp. 9007-9016, 2007.
[11] S.S. Habib, "Study of the parameters in electrical discharge machining
through response surface methodology approach," Appl. Math. Modelling, vol. 33, pp. 4397-4407, 2009.
[12] P. Fonda, Z. Wang, K. Yamazaki and Y. Akutsu, "A fundamental study
on Ti-6Al-4V-s thermal and electrical properties and their relation to EDM productivity," J. Mater. Process. Technol., vol. 202, pp. 583-589,
2008.
[13] M.K. Pradhan and C.K. Biswas, "Modelling of machining parameters
for MRR in EDM using response surface methodology," National
Conference on Mechanism Science and Technology: From Theory to
Application. National Institute of Technology, Hamirpur: 13-14
November, 2008.
[14] I. Puertas and C.J. Luis, "A study on the machining parameters optimisation of electrical discharge machining," J. Mater. Process. Technol., vol. 143-144, pp. 521-526, 2003.
[15] K.L Wu, B.H. Yan, J.W. Lee and C.G. Ding, "Study on the characteristics of electrical discharge machining using dielectric with surfactant," J. Mater. Process. Technol., vol. 209, pp. 3783-3789, 2009.
[16] R.C. Drof and A. Kusiak, "Handbook of design manufacturing and
automation," Singapore: A Wiley-Interscience Publication, 1994.
[17] S.H. Lee and X.P. Li, "Study of the effect of machining parameters on
the machining characteristics in electrical discharge machining of tungsten carbide," J. Mater. Process. Technol., vol. 115, pp. 344-358,2001.
[18] M. Kunieda, B. Lauwers, K.P. Rajurkar and B.M. Schumacher,
"Advancing EDM through fundamental insight into the process. CIRP Technol. vol. 54, no. 2, pp. 64-87, 2005.
[19] J.Y. Kao and Y.S. Tarng, "A neutral-network approach for the on-line
monitoring of the electrical discharge machining process," J. Mater.
Process. Technol. vol. 69, pp. 112-119, 1997.
[20] H.K. Kansal, S. Singh and P. Kumar, "Numerical simulation of powder
mixed electric discharge machining (PMEDM) using finite element
method," Math. Comp. Modell., vol. 47, pp. 1217-1237, 2008.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:56025", author = "M. M. Rahman and Md. Ashikur Rahman Khan and K. Kadirgama M. M. Noor and Rosli A. Bakar", title = "Modeling of Material Removal on Machining of Ti-6Al-4V through EDM using Copper Tungsten Electrode and Positive Polarity", abstract = "This paper deals optimized model to investigate the
effects of peak current, pulse on time and pulse off time in EDM performance on material removal rate of titanium alloy utilizing copper tungsten as electrode and positive polarity of the electrode. The experiments are carried out on Ti6Al4V. Experiments were
conducted by varying the peak current, pulse on time and pulse off time. A mathematical model is developed to correlate the influences of these variables and material removal rate of workpiece. Design of
experiments (DOE) method and response surface methodology
(RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through
analysis of variance (ANOVA). The obtained results evidence that as
the material removal rate increases as peak current and pulse on time
increases. The effect of pulse off time on MRR changes with peak ampere. The optimum machining conditions in favor of material removal rate are verified and compared. The optimum machining
conditions in favor of material removal rate are estimated and verified with proposed optimized results. It is observed that the developed model is within the limits of the agreeable error (about
4%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.", keywords = "Ti-6Al-4V, material removal rate, copper tungsten, positive polarity, RSM.", volume = "4", number = "11", pages = "1213-6", }
