OPTIMIZATION OF PROCESS

PARAMETERS OF DIE
SINKING EDM PROCESS ON
ALUMINUM MMC

GANDHAM VAMSHI KRISHNA,

21015A0316,
B.TECH 4th year 1st Sem
Department of Mechanical Engineering
JNTUH UCESTH
gandhamvamshikrishnagandham@gmail.com

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CONTENTS
 INTRODUCTION
 WORKING PRINCIPLE OF EDM
 FLOWCHART
 METAL MATRIX COMPOSITE PREPARATION
 EXPERIMENTAL SETUP
 RESULTS
 CONCLUSIONS
 REFERENCE’S

2
INTRODUCTION :
 Aluminum alloys are widely used in aerospace and automobile industries
due to their low density and good mechanical properties, better corrosion
resistance and wear, low thermal coefficient of expansion as compared to
conventional metals and alloys.
 The objective of the present work is to investigate the effects of the
various DEDM process parameters on the machining quality and obtain
the optimal sets of process parameters so that the quality of machined
parts can be optimized.
 The process parameters considered are Pulse Time on, Pulse Time off,
and peak current. The range of values varied are Time on – 100µsec, 200
µsec and 500 µsec, Time off – 200 µsec, 500 µsec, 900 µsec, Input
power –7amp, 15amp, 22amp..
 The optimization is done by using TAGUCHI technique by considering
L9 orthogonal array. Optimization is done using Minitab 19 software.

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WORK FLOWCHART:

Fig. 2 : Work Flow Chart [9]

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 ELECTRIC DISCHARGE MACHINING :
 EDM is a machining process which is an unconventional process in which
there is no direct contact between tool and work piece. [9]
 It is generally used to find the surface finish and material removal rate of
the work piece. In EDM process generally we have two processes likely
die sink process and wire cut process.[9]
 In die sink process with the help of electrode spark is generated and it
tends to generated to remove unwanted material from work piece and this
tends to make a good surface finish with unwanted material removal rate.
[9]
 In wire cut process generally material is removed by cutting process in
which a wire is used to remove the material. In EDM die sink process the
electrode which is used made of copper and generally whenever it is in
contact with work piece it removes the unwanted scrap and makes a good
surface finish. [9]

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WORKING PRINCIPLE OF EDM :

Fig. 1 : working principle of EDM [9]

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WORKING PRINCIPLE OF EDM :
Electrical discharge machining process works on the basic
principle of spark generation and metal removed by spark erosion.[9]
EDM spark erosion is same as electric spark which burn a small

hole in a piece of metal through which it contacts.[9]

The spark generated by this process produces heat, which

remove metal by erosion and evaporation. [9]

In this machining process both the work piece and tool must be

made by conductive material.[9]

In this process, work piece should be well electric conductive.

Only electric conductive material can be machined by this method.

The working of EDM is as follow.[9]

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METAL MATRIX COMPOSITE
PREPARATION
 Al7075 metal matrix is fabricated
by sand casting method. It is an
attractive and economical casting
technique which allows
conventional metal processing
route.[21]
 Al 7075 melted above 850 ºC in

a graphite crucible and the

reinforcements were preheated
up to same temperature for
proper mixing.[21] Fig. 3 : Mixing the powders (Stirring)
[21]

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METAL MATRIX COMPOSITE
PREPARATION

Fig. 4 : heated up to 8500C[21]

 Preheated boron carbide (6%) was mixed in the metal slurry manually
at 850 ºC.[21]

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 Fig. 5 : pouring the molten Fig. 6 : After pouring the molten metal
metal[21] (Filling)[21]

The molten metal poured in preheated moulds and allowed to cool.

Casted metal matrix was machined to remove cluster formation on the
surface and then cut into required dimension by using fan-saw cutting
machine.[21]

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 Milling Process For Finishing :

Fig. 7 : Milling process for finishing

After the Casting process based on our requirements of size we need to proceed for
further machining process

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DESIGN OF EXPERIMENTS:
 To obtain the ideal and accurate results DOE technique was used to collect
the data. In orthogonal array (L9) three process specifications Pulse on time
(µs), Pulse off time (µs) and Peak Current (Amp) were selected in this
study and MINITAB 19 software was used to analyze the results.[5]

Table. 1 : DOE worksheet[5]

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 Three rectangular plates of AL MMC material is used for investigation on
EDM machine according to the sequence created by the Taguchi design.
 The work piece and electrode was set up in the EDM machine and servo
mechanism is maintained.[5]
 After the completion of process EDM is stopped automatically and repeat
the procedure for next sample.[5]

Fig. 8 : work piece dimensions[5]

Fig. 9 : work pieces[5]

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 EXPERIMENTAL SETUP:
 Experiments have been performed in
order to investigate the effects of one or
more factors of the process parameters
on the surface finish of the wire cut
machined surface.[6]
 The main aim of the project is to
determine the influence of time on, time
off, and input power. The investigation
is based on surface roughness during
machining of Al MMC.[6]
Fig. 10 :Experimental setup[6]

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Die Sink EDM Process:
 The experiments were carried out using EDM
machine of model ZNC25 die sink EDM machine
with positive polarity and servo head
mechanism[9]
 Al MMC and copper tungsten electrode was used
as work piece and electrode for conducting the
experiments in die sink EDM machine. [9]
 The tool and work piece were connected to the
negative (cathode) and positive (anode) terminals
to the power controller of EDM machine. [9]
 After completion of each experiment tool and
work piece are removed, cleaned, dried and
weighed. [9] Fig. 11 : Die Sink EDM Process[9]
 Afer machining the holes in the work piece,
surface roughness is to be tested and material
removal rate is calculated by MRR formula[9]

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Final work pieces :

Fig. 12 : Final work pieces[9]

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RESULTS :
 Surface Roughness
 In this project most important output
performances in DEDM such as
Surface Roughness (Ra) is considered
for optimizing machining parameters.
[9]
 The surface finish value (in μm) was
obtained by measuring the mean
absolute deviation, Ra (surface
roughness) from the average surface
level using a Computer controlled
surface roughness tester. [9]
 Surface Finish Tester – Model
Table. 3 : Surface roughness values[9]
Surtronic.

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RESULTS :
Material Removal Rate
MRR can be defined as the ratio of volume of material removed to the machining
time.[9]

Where,
Wi = Initial weight of the work piece (gm)
Wf = Final weight of the work piece
p= Density of the work piece (g/mm3)

Table. 2 : Obtained MRR results[9]

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 Fig. 13 : options for analyze Taguchi design[20]

 Select smaller is better because of the surface roughness values are having
the smaller values giving the better surface finish and smoothness[20]

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Fig. 14 :main effects plot for SN ratios[20] Fig. 15 : main effects plot for means[20]

 Larger the SN Ratio smaller the Surface roughness so choose larger SN ratio for
Better Surface roughness Values
 Take optimum Value for the considarations

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 Fig. 16 : options for analyze Taguchi design[20]

 Select larger is better because of the MRR values are having the larger values
giving the maximum material removal rate

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Fig. 17 : main effects plot for SN ratios[20] Fig. 18 : main effects plot for means[20]

 Select larger is better because of the MRR values are having the larger values giving the
maximum material removal rate
 Larger SN value Larger the MRR
 Choose Larger SN value

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 TABLE. 4 : Conformation test results[20]

 Optimal conditions for minimum surface roughness (Ra) are a 200 mus pulse-on
time, 900 mus pulse-off time, and a peak current of -7 A to achieve the most
effective surface quality values.[20]

 Stimulation time -500 microseconds Pulseoff time -900 microseconds Peak

current -15 A Best rejection rate.[20]

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 • CONCLUSIONS:
 Analysis of the signal-to-noise size relationship shows that high
currents are the most predominant idea affecting surface
roughness (Ra) and material removal rate (MRR). Confirmation
As a result of, the experimental value was decided to be better
than the expected value. Therefore, the Taguchi are being
attempted as economic methods that can provide higher answers
to a single objective improvement problem..[20]

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