Performance Evaluation of Powder Metallurgy Electrode in Electrical Discharge Machining of AISI D2 Steel Using Taguchi Method
In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.
[1] D.F. Dauw, et al., Surface topography investigations by fractal analysis
of spark eroded electrically conductive ceramics, Ann. CIRP 39 (1)
(1990) 161-165.
[2] K.H. Ho, S.T. Newman, State of the art electrical discharge machining
(EDM), International Journal of Machine Tools & Manufacture, 43
(2003) 1287-1300.
[3] Semon G., A practical guide to electro-discharge machining, 2nd edition
Geneva: Ateliers des harmilles, 1975.
[4] A. Arthur et al., Using rapid prototyping to produce electrical discharge
machining electrodes, Journal of Rapid Prototyping, 2 (1) (1996) 4-12.
[5] Shankar Singh, S. Maheshwari , P.C. Pandey, Experimental
Investigations into Die- sinking Electric Discharge Machining of
Hardened AISI 6150 Tool Steel using different electrode Materials,
Strojnicky Casopis- Journal of Mechanical Engineering (Slovak), 56 (4)
(2005) 197-210.
[6] Shankar Singh, S. Maheshwari , P.C. Pandey, Some investigations into
the electric discharge machining of hardened tool steel using different
electrode materials ,Journal of Materials Processing Technology, 149
(2004) 272-277.
[7] Bayramoglu, B. and Duffil, A. W., Manufacturing linear and circular
contours using CNC EDM and fame type tools, International Journal of
Machine Tool and Manufacture, 35 (8) (1995) 1125-1136.
[8] I Ishida, Y. Takeuchi, L-shaped curved hole creation by means of
electrical discharge machining and an electrode curved motion
generator, International Journal of Advance Manufacturing Technology,
19 (4) (2002) 260-265.
[9] Rajurkar, K. P. and Pandit, S. M., Formation and ejection of EDM
debris, Transactions ASME , Journal of Engineering for Industry, 108
(1986) 22-26.
[10] A. Gangadhar, M. S. Shunmugam and P. K. Philip, Surface modification
in electro discharge processing with a powder compact tool electrode,
Wear, 143 (1) (1991) 45-55.
[11] J.S. Soni and G. Chakraverti, Experimental investigation on migration of
material during edm of die steel (T215 Cr12), Journal of Materials
Processing Technology, 56 (1996) 439-451.
[12] M. P. Samuel and P. K. Philip, Power metallurgy tool electrodes for
electrical discharge machining, International Journal of Machine Tool
and Manufacture, 37 (11) (1997) 1625-1633.
[13] Z. L. Wang, Y. Fang, P. N. Wu, W. S. Zhao and K. Cheng, Surface
modification process by electrical discharge machining with a Ti powder
green compact electrode, Journal of Material Processing Technology,
129 (1-3) (2002) 139-142.
[14] H. C. Tsai, B. H. Yan and F. Y. Huang, EDM performance of Cr/Cubased
composite electrodes, International Journal of Machine Tool and
Manufacture, (43) (3) (2003) 245-252.
[15] Hwa-Teng Lee, Fu-Chuan Hsu, Tzu-Yao Tai, Study of surface integrity
using the small area EDM process with a copper-tungsten electrode,
Materials Science and Engineering A, 364 (2004) 346-356.
[16] Jose Carvalho Ferreira, A study of die helical thread cavity surface finish
made by Cu-W electrodes with planetary EDM, International Journal of
Advance Manufacturing Technology, 34 (2007) 1120-1132.
[17] Yuan-Feng Chen, Han-Ming Chow, Yan-Cherng Lin and Ching-Tien
Lin , Surface modification using semi-sintered electrodes on electrical
discharge machining, International Journal of Advanced Manufacturing
Technology 36 (5-6) (2008) 490-500.
[18] M. S. Shunmugam, P. K. Philip and A. Gangadhar, Tribological
behaviour of an electrodischarge machined surface with a powder
metallurgy bronze electrode, Tribology International, 26 (2) (1993) 109-
113.
[19] Mohri, N., Saito, N. and Tsunekawa, Y., Metal surface modification by
EDM with composite electrode, Annals of CIRP, 42 (1) (1993) 219-222.
[20] Philip, P. K., Shunmugam, M. S. and Gangadhar, A., Surface
modification using electric discharge machining, Journal of Institute of
Engineers (India), 1993, 4, 23.
[21] J.L.Lin et al., Optimization of electrical discharge machining process
based on Taguchi method with fuzzy logics, Journal of Materials
Processing Technology, 102 (2000) 48-55.
[1] D.F. Dauw, et al., Surface topography investigations by fractal analysis
of spark eroded electrically conductive ceramics, Ann. CIRP 39 (1)
(1990) 161-165.
[2] K.H. Ho, S.T. Newman, State of the art electrical discharge machining
(EDM), International Journal of Machine Tools & Manufacture, 43
(2003) 1287-1300.
[3] Semon G., A practical guide to electro-discharge machining, 2nd edition
Geneva: Ateliers des harmilles, 1975.
[4] A. Arthur et al., Using rapid prototyping to produce electrical discharge
machining electrodes, Journal of Rapid Prototyping, 2 (1) (1996) 4-12.
[5] Shankar Singh, S. Maheshwari , P.C. Pandey, Experimental
Investigations into Die- sinking Electric Discharge Machining of
Hardened AISI 6150 Tool Steel using different electrode Materials,
Strojnicky Casopis- Journal of Mechanical Engineering (Slovak), 56 (4)
(2005) 197-210.
[6] Shankar Singh, S. Maheshwari , P.C. Pandey, Some investigations into
the electric discharge machining of hardened tool steel using different
electrode materials ,Journal of Materials Processing Technology, 149
(2004) 272-277.
[7] Bayramoglu, B. and Duffil, A. W., Manufacturing linear and circular
contours using CNC EDM and fame type tools, International Journal of
Machine Tool and Manufacture, 35 (8) (1995) 1125-1136.
[8] I Ishida, Y. Takeuchi, L-shaped curved hole creation by means of
electrical discharge machining and an electrode curved motion
generator, International Journal of Advance Manufacturing Technology,
19 (4) (2002) 260-265.
[9] Rajurkar, K. P. and Pandit, S. M., Formation and ejection of EDM
debris, Transactions ASME , Journal of Engineering for Industry, 108
(1986) 22-26.
[10] A. Gangadhar, M. S. Shunmugam and P. K. Philip, Surface modification
in electro discharge processing with a powder compact tool electrode,
Wear, 143 (1) (1991) 45-55.
[11] J.S. Soni and G. Chakraverti, Experimental investigation on migration of
material during edm of die steel (T215 Cr12), Journal of Materials
Processing Technology, 56 (1996) 439-451.
[12] M. P. Samuel and P. K. Philip, Power metallurgy tool electrodes for
electrical discharge machining, International Journal of Machine Tool
and Manufacture, 37 (11) (1997) 1625-1633.
[13] Z. L. Wang, Y. Fang, P. N. Wu, W. S. Zhao and K. Cheng, Surface
modification process by electrical discharge machining with a Ti powder
green compact electrode, Journal of Material Processing Technology,
129 (1-3) (2002) 139-142.
[14] H. C. Tsai, B. H. Yan and F. Y. Huang, EDM performance of Cr/Cubased
composite electrodes, International Journal of Machine Tool and
Manufacture, (43) (3) (2003) 245-252.
[15] Hwa-Teng Lee, Fu-Chuan Hsu, Tzu-Yao Tai, Study of surface integrity
using the small area EDM process with a copper-tungsten electrode,
Materials Science and Engineering A, 364 (2004) 346-356.
[16] Jose Carvalho Ferreira, A study of die helical thread cavity surface finish
made by Cu-W electrodes with planetary EDM, International Journal of
Advance Manufacturing Technology, 34 (2007) 1120-1132.
[17] Yuan-Feng Chen, Han-Ming Chow, Yan-Cherng Lin and Ching-Tien
Lin , Surface modification using semi-sintered electrodes on electrical
discharge machining, International Journal of Advanced Manufacturing
Technology 36 (5-6) (2008) 490-500.
[18] M. S. Shunmugam, P. K. Philip and A. Gangadhar, Tribological
behaviour of an electrodischarge machined surface with a powder
metallurgy bronze electrode, Tribology International, 26 (2) (1993) 109-
113.
[19] Mohri, N., Saito, N. and Tsunekawa, Y., Metal surface modification by
EDM with composite electrode, Annals of CIRP, 42 (1) (1993) 219-222.
[20] Philip, P. K., Shunmugam, M. S. and Gangadhar, A., Surface
modification using electric discharge machining, Journal of Institute of
Engineers (India), 1993, 4, 23.
[21] J.L.Lin et al., Optimization of electrical discharge machining process
based on Taguchi method with fuzzy logics, Journal of Materials
Processing Technology, 102 (2000) 48-55.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:49187", author = "Naveen Beri and S. Maheshwari and C. Sharma and Anil Kumar", title = "Performance Evaluation of Powder Metallurgy Electrode in Electrical Discharge Machining of AISI D2 Steel Using Taguchi Method", abstract = "In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.
", keywords = "Electrical discharge machining (EDM), Powder Metallurgy (PM), Taguchi method, Material Removal Rate (MRR), Surface Roughness (SR).", volume = "2", number = "2", pages = "140-5", }
