ELECTRODE WEAR IN EDM-PART 2
Keywords:
Electric discharge machining (EDM), Electrode wear- Ton, Duty cycle, FlushingAbstract
Electric Discharge machining (EDM) is a non-traditional production method that has widely used in the production of dies throughout the world in recent years and has achieved remarkable success in the manufacturing of conductive materials for the modern industry. The most important performance measure in EDM is the tool wear among other measures material removal rate and surface roughness. In most of the EDM Process, cost of the tool is more than 70 % of the total operation cost, which generate the necessity of minimization of tool wear and it should be taken into very careful consideration while planning and designing EDM operation. The objective of this paper is to study the optimization of machining process parameters to prevent Electrode wear /minimize electrode (tool) wear in Electro-discharge Machining. In EDM, the tool wear problem is very critical since the tool shape degeneration directly affects the final shape of the die cavity. In this paper, the effect of different machining variables on the electrode wear in EDM like flushing rate, type of flushing, Ton,duty cycle. Current, gap & voltage were studied. The experiments were conducted on EN 31 & round copper tools with kerosene as dielectric under center flushing with varying different parameters. The experiment has shown that machining parameters & flushing conditions had large effect on tool wear (electrode wear).
Downloads
References
Zarepour H, Tehrani A F, Karimi D and Amini S (2007), “Statistical Analysis on Electrode Wear in EDM of Tool Steel DIN 1.2714 used in Forging Dies”, Journal of Material Processing Technology, Vol. 187-188, pp 711-714.
Shu K M and Tu G C (2003), “Study of Electric Discharge Grinding using Metal Matrix Composite Electrode”, International Journal of Machine Tool Manufacturing, Vol. 43, pp 845-854.
Yan B H, Tsai H C and Huang F Y (2005), “The Effect of EDM of Dielectric of a Urea Solution in Water on Modified Surface of Titanium”, International Journal of Machine Tool Manufacturing, Vol. 45(2), pp 194-200.
Ho K H and Newman S T (2003), “State of Art Electric Discharge Machining (EDM)”, International Journal Machine Tool Manufacturing, Vol. 43(13), pp 1287-130.
McGeough J A (1988), “Advanced Methods of Machining”, Chapman and Hall, New York.
Kalpakjian S and Schmid S R (2001), “Manufacturing Engineering and Technology”, 4th Edn. Prentice Hall, Upper saddle River
Khanra A K, Sarker B R, Bhattacharya B, Parthak L C and Godkhindi M M (2007), “Performance of ZRB2-Cu Composite as an EDM Electrode”, Journal of Material Processing Technology, Vol. 1831, pp 122-126.
Kunieda M and Muto H (2000), “Development of Multi-Spark EDM". ANN CIPR, Vol. 49(1), pp 119-122.
Marafona J (2007), “Black Layer Characterization and Electrical Discharge Machining”, Journal of Material Processing Technology, Vol. 184, pp 27-31.
Luis C J, Puertas I and villa G (2005), “Material Removal Rate and Electrode Wear Study on EDM of Silicon Carbide”, Journal of Material Processing Technology, Vol. 164-165, pp 889-896.
