Document Type : Research Paper
Authors
Production Engineering and Metalluragy - Iraq
Abstract
The present work is aimed to improve the surface cracks density of electrical discharge machining (EDM) by Electrical Discharge Machining (EDM)/Electrochemical Machining (ECM) EDM/ECM hybrid process. A hybrid method of EDM-ECM combined processing involve EDM shaping as well as electrochemical machining (ECM) finishing, also, they are conducted in sequence one same machine tool, same electrode, yet on the different dielectric. In this study, the used workpiece material is the A2-Tool Steel material, while the electrode material is copper. The influence of controllable parameters could be identified via response surface methodology (RSM), these controllable effects include: pulse current, pulse on time, pulse off time, gap, voltage, and electrolyte concentration on surface cracks density (SCD). It has been noticed that model has been developed by RSM adequacy is acceptable because the coefficient of determination is closest to one for SCD, whereas the optimal solution achieved by Desirability Function Analysis (DFA) are (current =42 A, pulse-on time =100 , and pulse-off time =50 )in addition to that, the generated surface doesn’t have any crack which has been generated via EDM are removed entirely through ECM finishing.
Keywords
Main Subjects
International Journal of Machine Tools & Manufacture
Simultaneous micro-EDM and micro-ECM in lowresistivity deionized water, vol. 54–55, pp. 55–65,
2012.
[2] Hassan Abdel Gawad El-Hofy, Advanced
Machining Processes; Non -Traditional and Hybrid
Machining Processes, first edition, published by
McGraw-Hill Companies, 2005.
[3] K. Morankar and R. Shelke, „Optimization of
Electrical Discharge Machining Process Parameters
using JIS S CM420 low alloy steel by Response
Surface Methodology‟, International Journal of
Research in Engineering & Advanced Technology,”
Vol. 5, No. 1, pp. 58–63, 2017.
[4] V. Babu, J. S. Soni, and M. L. Rao, "Analysis and
evaluation of heat affected zones ( HAZ ) of the workpiece surface machined using different electrode
by Die-sinking EDM
of EN-31 die steel", International Journal Of
Engineering And Science (IJES),Vol.05,No.3, pp. 37–
42, 2016.
[5] M. K. Pradhan,„Estimating the effect of process
parameters on surface integrity of EDM ed AISI D2
tool steel by response surface methodology coupled
with grey relational analysis‟,International Journal of
Advanced Manufacturing Technology, Vol.67 pp.
2051–2062, 2013.
[6] M. Boujelbene, E. Bayraktar, W. Tebni, and S. Ben
Salem, „Influence of machining parameters on the
surface integrity in electrical discharge machining‟,
International Scientific Journal published by the World
Academy of Materials and Manufacturing Engineering,
Vol. 37, No. 2, pp. 110–116, 2009.
[7] G. K. Mohana Rao, S. Satyanarayana, and M
Praveen,„Influence of Machining Parameters on
Electric Discharge Machining of Maraging Steels – An
Experimental Investigation‟, Proceedings of the World
Congress on Engineering, vol. II, pp.1-6, 2008.
[8] B. Bhattacharyya, S. Gangopadhyay, and B. R.
Sarkar,„Modelling and analysis of EDM ED job surface
integrity‟, Journal of Materials Processing Technology,
Vol. 189, pp. 169–177, 2007.
[9] J. Jeykrishnan, B. V. Ramnath, C. Elanchezhian,
and S. Akilesh, „Parametric analysis on Electrochemical machining of SKD-12 tool steel‟, 5th
International Conference of Materials Processing and
Characterization, Vol. 4, No. 2, pp. 3760–3766, 2017.
[10] M. Zohoor, S. Jalili, A. Alipour, and R.
Mosallanejad, “„Effect of Electrolyte Type on
Electrochemical Machining of 304 Steel‟, International
Journal of Advances in Engineering Research
(IJAER),” No. 12, pp. 20–39, 2016.
[11] S. H. Surekar and S. G. Bhatwadekar,
„Optimization of Parameters in Electrochemical
Machining of Ni-Base Superalloy‟, International
Journal of Research in Aeronautical and Mechanical
Engineering, Vol. 4, No. 1, pp. 72–80, 2016.
)
