Professional Documents
Culture Documents
A Study of Hole Drilling On Stainless Steel AISI 431 by EDM Using Brass Tube Electrode
A Study of Hole Drilling On Stainless Steel AISI 431 by EDM Using Brass Tube Electrode
http://go.to/Research
a*
ARTICLEINFO
ABSTRACT
Article history:
Received 23 August 2011
Received in revised form
23 September 2011
Accepted 27 September 2011
Available online
27 September 2011
Keywords:
EDM, AISI 431,
Electrode,
Brass,
Taper
1 Introduction
Nowadays, stainless steel AISI 431 is a popular material used in many industries such as
water pump, kitchenware, and fittings manufacturing industries(Jeong and Min, 2007).
Because of its durability to environment. However, as drilling a hole on stainless steel is
difficult due to its properties. Therefore, various meso or micro machining methods have been
introduced, such as machining, ultrasonic, electrochemical, laser, electrical discharge
machining. Especially an electrical discharge machining (EDM) is one of non-contact thermal
process, which has advantages such as high-precision machining of conductive materials and
*Corresponding author (A. Muttamara). Tel/Fax: +66-2-5643001 Ext.3189. E-mail addresses:
mapiwat@engr.tu.ac.th.
2011. International Transaction Journal of Engineering,
Management, & Applied Sciences & Technologies. Volume 2 No.4.
ISSN 2228-9860.
eISSN 1906-9642. Online Available at http://TuEngr.com/V02/471-481.pdf
471
tan
Where
(1)
D is hole entrances,
d is hole exits, and
L is hole length.
This research focuses on influence of machining variables affecting material removal rate
(MRR), electrode wear rate (EWR), and taper on martensitic stainless steel AISI 431.
2 ExperimentalProcedure
The experiments were carried out on 35 mm of hole depth of martensitic stainless steel
AISI 431with ZNC-EDM model JM325DZ manufactured by Joemars company, as shown in
Figure2(a). The EDM was carried out on meso-scale machining with a brass tube electrode as
472
outside diameter of 1 mm, inner hole diameter of 0.3 mm for flushing by dielectric fluid to
remove wear debris and heat ventilation size as shown in Figure 2(b). Principle of tube
electrode drilling is shown in Figure 2(c). The experiments were carried out in the de-ionised,
because of the advantage of material removal rate (Diver et al. 2004).
The chemical
compositions and essential physical properties are shown in Table 1 and Table 2, respectively.
Table 3 shows the physical properties of an electrode.
contained in Table 4.
473
Si
0.6
0.17
Mn
Cr
Ni
1.0
17.0
2.0
0.03
0.04
Properties
Value
Density(x1000 Kg/m3)
7.8
25
Elastic modulus(GPa)
200
25
965
Thermal conductivity(W/m K)
20.2
100
Electrical resistivity(10-9 m )
720
25
( oC)
Cu-Zn (60-40)
910
Density (g/cm3)
10.98 g / cm3
78~85
Hardness(HRB)
93
648
Values
+
1-9
10,30,50,90
10-90
2-10
20-60
100
De-ionised water
3 ResultsandDiscussion
As for the experiments were conducted under five process factors such as ; electrical
current, on-time, duty factor, water pressure and servo rate, the data were analyzed as follows:
474
3.1 AnalysisofWaterPressure
The experiments were conducted by varying the water pressure 20, 30, 40, 60 kg/cm2 and
fixing parameter of current at 9 A, on-time at 10 s, duty factor at 75 %, and servo rate at 2 mm/
sec. High water pressure has influence to cutting process makes gain of the drilling speed. It
increases electrode wearing ratio but reduces taper of drilling wall as shown in Figure3(a-c).
Because high water pressure make debris dispose out from clearance space between a
workpiece and electrode surfaces. Consequently, complete spark often occurred and thus the
material removal rate increased (Diver et al. 2004).
3.2 Analysisofcurrent
In this experiment, we consider of each parameter by varying current 1, 2, 3, 5, 7, 9A and
fixing of parameter of on-time at 10s, duty factor at 75%, servo rate at 2 mm/sec, and water
pressure at 40kg/cm2. As the results in Figure 4(a), it indicates that the increase of material
removal rate resulted from the raise in current. High current increases material removal rate
ratio and electrode wear ratio as shown in Figure 4(b) (Han et al. 2004). From Figure 4(c),
*Corresponding author (A. Muttamara). Tel/Fax: +66-2-5643001 Ext.3189. E-mail addresses:
mapiwat@engr.tu.ac.th.
2011. International Transaction Journal of Engineering,
Management, & Applied Sciences & Technologies. Volume 2 No.4.
ISSN 2228-9860.
eISSN 1906-9642. Online Available at http://TuEngr.com/V02/471-481.pdf
475
taper of drilled hole is increased because the discharges produce thermal energy according to an
electrical current (Fukuzawa et al. 2004). As estimation of the current increasing while the
cross section is still constant, it makes gain of the density of current per cross section area (Sen
and Shan, 2005), (Guitrau,1997).
3.3 Analysisofservorate
In this experiment, we consider factor of servo rate 2, 4, 6, 8, 10 mm/sec and fix parameter
of current 9 A, on-time at 10 s, duty factor at 75 %, and water pressure at 40 kg/cm2. As
shown in Figure 5(a), it was found that the increasing of servo rate lead to decreasing of MRR
because the spark requires an appropriate gap. If servo rate is set up over the required value,
narrow gap will be occurred thus the spark is incomplete or short circuit (Choi and Kim, 1998),
(Han et al. 2004). When servo rate increases, electrode wear and taper increases as shown in
Figure 5(b-c). It can be explained that EDM sparking on servo rate in the narrow discharge gap
changes the contact angle of holes wall and the edge of electrode, observed in Figure 5(c).
476
Figure 5(d) shows the phenomena of EDM drilling on shallow and deep holes (Yu et al. 2009).
3.4 AnalysisofDutyFactorandOnTime
The duty factor, which means the ratio between pulse duration and pulse cycle time exerts
an important role on the performance of EDM as shown in Figure6 (a). In this experiment, we
consideration of each parameters by varying duty factor 10, 15, 20, 35, 45, 60, 75, 90 %, on
time 10, 30, 50, 90 s, and fixing parameters of current at 9 A, servo rate at 2 mm/sec, and water
pressure at 40 kg/cm2, respectively. As can be seen in Figure6 (b-c), the results were found that
the each on-time was suitable for only a specific duty factor. MRR increases with increasing of
duty factor of each on-time. However, increasing of duty factor leads to decreasing of EWR and
taper. Moreover, if increasing of on-time less than 30 s, it still affects to MRR increases. At 75
% of duty factor for on-time 30 and 50 s, they give same values of MRR. However, these
parameters results in low EWR and taper.
477
Figure 7 shows impressions of the result from the experiment test with current at 9A,
on-time at 10s, duty factor at 75%, servo rate at 2 mm/sec, and water pressure at 40 kg/cm2,
respectively. It shows the feature of taper could be achieved. Diameter at electrode entry was
between 1.08 mm and 0.97 mm as shown in Figure 7(a). Figure 7(b) shows result meso-hole
machined exit. Figure 8 shows an image of a section meso-hole machined using the same
condition.
4 Conclusion
As the results of the material removal rate, electrode wear, taper in the drill hole meso-scale
by brass tube electrode, it can conclude that:
1. The MRR is lower when increasing of servo rate.
2. The taper of hole increases with increasing of electrical current and servo rate.
*Corresponding author (A. Muttamara). Tel/Fax: +66-2-5643001 Ext.3189. E-mail addresses:
mapiwat@engr.tu.ac.th.
2011. International Transaction Journal of Engineering,
Management, & Applied Sciences & Technologies. Volume 2 No.4.
ISSN 2228-9860.
eISSN 1906-9642. Online Available at http://TuEngr.com/V02/471-481.pdf
479
5 Acknowledgement
This work was supported by the National Research University Project of Thailand Office
of Higher Education Commission and the National Research Council of Thailand (NRCT).
6 References
Ali S., Hinduja S., Atkinson J., Pandya M. (2009). Shaped tube electrochemical drilling of good
quality holes. CIRP Annals - Manufacturing Technology , 58, 185-188.
Bilgi D.S., Jain V.K., Shekhar R., Kulkarni A. (2007). Hole quality and inter-electrode gap
dynamics during pulse current electrochemical deep hole drilling. International Journal
of Advanced Manufacturing Technology, 34, 79-95.
Choi I-H.,Kim J-D. (1998). A study of the characteristics of the electrochemical deburring of a
governor-shaft cross hole. Journal of Material Processing Technology, 75, 198-203.
Diver C., Atkinson J., Helml H.J., Li L. (2004). Micro-EDM drilling of tapered hole for
industrial applications. Journal of Material Processing Technology, 149, 296-303.
Fukuzawa Y., Mohri N., Tani T. and Muttamara A. (2004). Electrical discharge machining
properties of noble crystals. Journal of Materials Processing Technology, 149(1-3), 393
-397.
Guitrau E.B. (1997). The EDM Handbook. Handser Gardner publication Cincinnati, 19-54.
Han F., Wachi S., Kunieda M. (2004). Improvement of machining characteristics of microEDM using transistor type isopulse generator and servo feed control. Precision
Engineering, 28, 378385.
Jeong Y. H., Min B. K. (2007). Geometry prediction of EDM-drilled holes and tool electrode
shapes of micro-EDM process using simulation. International Journal of Machine Tool
and Manufacture , 47, 187-1826.
Muttamara A., Fukuzawa Y., Mohri N., and Tani T. (2009). Effect of electrode Materials on
EDM of Alumina. Journal of Materials Processing Technology, 209, 2545-2552.
Muttamara A., Janmanee P., and Fukuzawa Y.(2010). A Study of MicroEDM on Silicon
Nitride Using Electrode Materials. International Transaction Journal of Engineering,
Management, & Applied Sciences & Technologies, 1(1), 1-7.
Rajasekhar A., Madhusudhan Reddy G., Mohandas T. (2009). V.S.R. Murti. Influence of
austenitizing temperature on microstructure and mechanical properties of AISI 431
martensitic stainless steel electron beam welds. Materials and Design, 30, 1612-1624.
480
Sen M., Shan H.S.(2005). A review of electrochemical macro- to micro-hole drilling processes.
International Journal of Machine Tool and Manufacture,45, 137-152.
Sharma S., Jain V.K., Shekhar R. (2002). Electrochemical drilling of inconel super alloy with
acidified NaCl electrolyte. International Journal of Advanced Manufacturing
Technology, 19, 492-500.
Yu Z.Y., Zhang Y., Li J., Luan J., Zhao F., Guo D. (2009). High aspect ratio micro-hole drilling
aided with ultrasonic vibration and planetary movement of electrode by micro-EDM.
CIRP Annals - Manufacturing Technology, 58, 213-216.
Peer Review: This article has been internationally peer-reviewed and accepted for publication
according to the guidelines given at the journals website.
481