Effects of Pulse Duration and Current on EDM Process of Allegheny Ludlum D2 Tool Steel

Abstract:

The purpose of this paper is to study the effect of current on performance of EDM process of Allegheny Ludlum D2 Tool Steel (UNS T30402). The effect of varying the machining parameters on the machining responses such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (Ra) have been investigated. In this study, circular shape of copper was used as an electrode with surface area of 100mm². The experiments were repeated for three different values of pulse duration (100µs, 200µs and 400µs) with combination of three different values of discharge current (12A, 16A and 24A). It was found that the pulse duration and current give significant effect on MRR, EWR and Ra. An increase in the pulse durations causes an increase in the MRR and Ra, but a decrease in the EWR. Meanwhile, the effect of currents on EDM performance shows that the increasing currents led to an increase in the MRR, EWR and Ra.

• Periodical: Applied Mechanics and Materials (Volume 315)
• Pages: 369-373
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.315.369
• Online since: April 2013
• Authors: S. Sulaiman, A.A. Khan, M.A. Razak, M.R. Ibrahim, M.S. Yusof
• Keywords: Allegheny Ludlum D2 Tool Steel, EDM, Electrode Wear Rate, Material Removal Rate (MRR), Surface Roughness (SR), Wear Rate

References

[1] Snoyes, R., Van Dijck, F. (1971). Investigations of EDM operations by means of thermo mathematical models", Annals of CIRP 20 (1), p.35.

[2] Dhanik, S., Joshi, S.S., Ramakrishnan, N. and Apte, P.R., 2005. Evolution of EDM process modelling and development towards modelling of the micro-EDM process, International Journal of Manufacturing Technology and Management, Volume7, No. 2/3/4, pp.157-180.

DOI: 10.1504/ijmtm.2005.006829

[3] Ho, K.H. and Newman, S.T., 2003. State of Art Electrical Discharge Machining (EDM), International Journal of Machine Tools and Manufacture, Volume 43, No. 13, pp.1287-1300.

DOI: 10.1016/s0890-6955(03)00162-7

[4] Marafona, J. and Wykes, C.A., 2000. New Method of Optimizing Material Removal Rate using EDM with Copper-tungsten Electrodes, International Journal of Machine Tools and Manufacture, Volume 40, No. 2, pp.153-164.

DOI: 10.1016/s0890-6955(99)00062-0

[5] Mohan, B., Rajadurai, A. and Satyanarayana, K.G., 2002. Effect of sic and rotation of electrode on electric discharge machining of Al-sic composite. Journal of Materials Processing Technology, 124(3), 297-304.

DOI: 10.1016/s0924-0136(02)00202-9

[6] Lajis, M. A., Radzi , H.C.D.M., Amin, A.K.M. N. (2009). The implementation of Taguchi method on EDM process of Tungsten Carbide, European Journal of Scientific Research, ISSN 1450-216X, 26 (4): 609-617.

[7] Kao, J.Y., Tsao, C.C., Wang, S.S., Hsu, C.Y. (2010). Optimization of the EDM parameters on machining Ti–6Al–4V with multiple quality characteristics, Int J Adv Manuf Technol., 47: 395–402.

DOI: 10.1007/s00170-009-2208-3

[8] Khan A.A. (2008). Electrode wear and material removal rate during EDM of aluminum and mild steel using copper and brass electrodes, Int J Adv Manuf Technol (2008) 39: 482–487.

DOI: 10.1007/s00170-007-1241-3

[9] Godfrey C (2005) Onwubolu. A note on surface roughness prediction model in machining of carbon steel by PVD coated cutting tools,. Am J App. Sci 2(6): 1109-1112.

DOI: 10.3844/ajassp.2005.1109.1112

[10] Sohani, M.S., Gaitonde, V.N., Siddeswarappa, B., Deshpande, A. S. (2009).

[11] Ahsan Ali Khan, Mohammad Yeakub Ali and Md. Mohafizul Haque (2009).