ENGINEERING & TECHNOLOGY IN INDIA

Strength for Today and Bright Hope for Tomorrow

Volume 1:1 February 2016

Chief Editor
Dr. D. Nagarathinam, M.E., Ph.D.

Editors
         Dr. P. N. Rajnarayanan, M.E., Ph.D.
         Dr. K. Sudalaimani, M.E., Ph.D.
         Dr. S. Ramanathan, Ph.D.

Language and Style Advisors
         G. Baskaran, Ph.D.
         Sam Mohanlal, Ph.D.

Executive Editor
         M. S. Thirumalai, Ph.D.

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M. S. Thirumalai

An Experimental Study on the Influence of Machining Parameters When Machining Tool Steel Using Die-Sinking EDM

C Shyamlal, K Somasundaram, R Prabakaran, and M Karthi

Abstract

Copper tungsten electrode of 14 mm diameter was used in electrical discharge machining (EDM) of P 20 tool steel at different current, pulse-on time and pulse-off time settings with the objective of determining possible correlation between EDM parameters and the machinability factors. Experiments were conducted using Taguchi method. Each test was performed for 15 mins and EDF-K diamond oil was used as the dielectric fluid. The material removal rate of the workpiece was obtained based on the calculation of mass loss per machining time and surface roughness was obtained based on the average of readings. It was found that material removal rate as well as surface roughness was dependent on peak current, pulse-on time and pulse-off time. High peak current, low pulse-on time and high pulse-off time was found suitable for minimum surface roughness. High peak current, high pulse-on time and low pulse-off time was found suitable for maximum material removal rate.

Keywords: Sinking EDM, Peak current, Pulse-on time, Pulse-off time, Taguchi method, Material removal rate, Surface roughness.

Introduction

Recently, many researchers have done their work in the field of electrical discharge machining by machining various combinations of workpieces and tool materials in order to reduce the wear of electrode and to increase the material removal rate in the workpiece [3]. From the researches, it is observed that by manufacturing composite electrode, it is possible to reduce wear and to increase the material removal rate. In this paper, it is decided to use copper tungsten electrode and P20 tool steel [11] to find the maximum material removal rate and minimum surface roughness. EDM is successfully used in the field of tool and die making. Pure electrode materials find considerable advantage in the EDM process because of their electrical conductivity. But wear in those electrodes will be more.

Hence, to reduce the wear electrodes are being manufactured in polymer, composite materials and in alloy materials like copper tungsten, silver tungsten. But copper tungsten electrode is economical compared to other alloy electrodes and is being used in the industries world wide. Hence, as wear is less in copper tungsten [1] electrodes this study is focused on material removal rate and surface roughness in workpiece when machining tool steel using copper tungsten electrode.

This is only the beginning part of the article. PLEASE CLICK HERE TO READ THE ENTIRE ARTICLE IN PRINTER-FRIENDLY VERSION.

C Shyamlal
shyamlalchandrasekaran@gmail.com

K Somasundaram
sundarsubi@gmail.com

R Prabakaran
prabakaranmechanical@gmail.com

M Karthi
karthicadcam@gmail.com

Assistant Professors
Department of Mechanical Engineering
Theni Kammavar Sangam College of Technology
Theni
Tamilnadu 625 534
India

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