Analysis of Energy Distribution in Sinker EDM Process

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GRD Journals- Global Research and Development Journal for Engineering | Volume 1 | Issue 12 | November 2016 ISSN: 2455-5703

Analysis of Energy Distribution in Sinker EDM Process Kumari Nilu Department of Mechanical Engineering Saroj Institute of Technology and Management, Lucknow- 226021, U.P (India) Mr. Abhishek Singh Department of Mechanical Engineering Saroj Institute of Technology and Management, Lucknow226021, U.P (India)

Mr. Amit Kumar Singh Department of Mechanical Engineering Saroj Institute of Technology and Management, Lucknow226021, U.P (India)

Abstract Electro Discharge Machining (EDM) is used for machining electrically conducting /semi conducting, tough and brittle material .This process is best suited for making intricate cavities and contour, dies, section of complex geometry, moulds. The work piece material selected for this study is mild steel and tool is copper electrode. Dielectric flow rate, discharge current, pulse on time, pulse off time is considered as input parameters. In the present work ANOVA analysis is used to study the significance of process variable on Material Removal Rate (MRR) and Tool Wear Rate (TWR) by using simple conduction equations, we can calculate the energy transferred to each for material removal rate and tool wear rate. Also energy transferred to work piece, tool and dielectric fluid can be calculated by using conduction equation, convection equation, energy carried away by debris, and the best suited input parameters can be found for the maximum energy transfer to work piece. After than energy responsible for tool wear were calculated and the optimum parameter are found in order to minimize the tool wear The energy distribution in the electrical discharge machining (EDM) process is most important phenomenon for study the variation of fraction of input discharge energy with the help of thermo-mathematical models during EDM of mild steel by varying the machining parameter current and pulse duration. Keywords- EDM, Conduction, Convection, MRR, TWR

I. INTRODUCTION Electric discharge machining is nonconventional manufacturing process uses spark for material removal.EDM is used for deep cutting, for sharp inside corner complicated shape, mould making tool and die industries, machining of geometrically complex, hard material with accuracy, nonconventional machining process uses sound, light, electrical and chemical form of energy .High accuracy surface finish can be obtain with non-conventional machine where electrical form of energy is used. One of the main advantages of EDM is a consequence of the thermal process. It is based on Eroding material by melting and evaporation, so the hardness of the work piece is no limitation for machining. Even the hardest steel grades can be machined with almost same machining speed as for softer steels. Drilling, milling, grinding and other conventional machining operations are replaced by electric discharge machining. Tool or electrode, work piece dielectric liquid are used for extremely tough and brittle electrically conductive materials in the process of making moulds, dies, section of complex geometry and intricate shapes desired shape is obtained by using spark process is not making actual contact between tool and work piece .The electric spark produces huge amount of heat melting work piece but it must be controlled carefully .The increase in temperature during working of EDM is up to 800-1200℃. No direct contact between electrode and work piece so no stress is produced. EDM process is used in aerospace automobile and electronic industry to making prototype and production parts of difficult material .For fulfilling this requirement EDM machine has been developed. in the field of medical and surgical instrument, sports aerospace, automobile and electronic industries including automobile and electronic industries automotive R & D areas EDM is used. Super alloys, high-tech ceramics heat resistant steels can be easily machined with EDM.

II. LITERATURE REVIEW H. Singh et al. (2012) study that energy distribution in the Electrical Discharge Machining (EDM) process influences the material removal rate, and other machining characteristics like crater geometry, relative wear ratio and surface roughness. During this process the electrical energy is converted into heat energy and this energy is distributed among the electrode, work piece and the dielectric fluid. The fraction of the energy which is transferred to the work piece is the useful energy and this energy should be maximum, for optimum utilization of energy. This fraction of energy is one of the important parameters used in the existing

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