Engineering and Technology Journal

The experimental work of this paper leads to electrical discharge machining (EDM). A system for machining in this process has been developed. Many parameters are studied such as current, pulse on-time, pulse off time of the machine. The main aim of this work is to calculate the metal removal rate (MRR) and electrode wear rate (EWR) using copper, electrodes when machining tool steel H13 specimens of a thickness (4mm).
Different current rates are used ranging from (30, 42, and 54) Amp, pulse on-time ranging from (75, 100, and 125) and pulse off time ranging from (25, 50, and 75) found that high current gives large electrode wear and metal removal rate and. The experiment design was by Taguchi Method. From an analysis of variance (ANOVA) the more active influence of input factors on the outputs is currently for metal removal rate (MRR) (58%) and electrode wear rate (EWR) (57)

In the current paper, an experimental analysis on Al-sheet (AA 1050) with thickness 0.9 mm to reveal the effect of relevant forming factors on the formed thickness in two-point incremental forming (TPIF) process has been conducted. The formed thickness of pyramid-like shapes was analyzed by studying seven variables: die geometry, tool diameter, tool path, stepover, tool shape, lubricant and slope angle. The proposed analysis utilizes Box-Behnken design of experiment (BBD), main effects plot (MEP) and analysis of variance (ANOVA) for sake of studying the influences of the seven forming factors on the resulted thickness. The results of these analyses have indicated that the most significant factor affecting the formed thickness is the die geometry followed by tool shape, lubricant and stepover respectively for both slope angles of the pyramid. In addition, it has been found that the other variables have also significant effects on the formed thickness at both slopes of the pyramids produced.