Taguchi based Modeling and Optimization of Tool Wear Rate in Die-Sink EDM

Autores

  • Navdeep Malhotra School of Mechanical Engineering, Shri Mata Vaishno Devi University, Katra, J&K, India
  • Hari Singh
  • Sona Rani

Palavras-chave:

EDM, optimization, Taguchi technique, tool wear rate

Resumo

With the increasing demand for new, hard, high strength, and temperature-resistant materials in various engineering applications, especially in the field of mold manufacturing, aeronautic, automobile and die manufacturing industries, the development and application of electro-discharge machining (EDM) has become increasingly important to machine such difficult to machine hard materials. In this paper, the machining of EN-31 Die steel using EDM with a copper electrode by using Taguchi’s experimental design and analysis has been reported. The Taguchi method L27 is used to formulate the experimental layout, analyse the effect of each parameter on the machining characteristics, and predict the optimal choice for EDM parameters such as current, pulse on time, voltage, spark gap, duty cycle and flushing pressure. Effect of these six parameters and their interaction also has been studied to select the levels of process parameters to obtain optimum tool wear rate, because tool cost is approximately 70% of the total processing cost in EDM process. Tool wear directly affects the surface roughness and accuracy because in EDM process the replica of the  tool is generated on the material/job. In this study, it is observed that current has significant effect on tool wear rate followed by pulse on time, voltage and flushing pressure. Flushing pressure and voltage have least significant effect on tool wear rate. It is also observed that spark gap and duty cycle have negligible effect on tool wear rate  Keywords; EDM, optimization, Taguchi technique, tool wear rate

Biografias do Autor

  • Navdeep Malhotra, School of Mechanical Engineering, Shri Mata Vaishno Devi University, Katra, J&K, India
    F/I Central WorkshopShri Mata Vaishno Devi University, Katra (Jammu), India15 years Teaching Experince.Quallification: PhD, M.E, MPM, PGdPE, PGdMM, BESpecialization: Advanced Manufactring Proceses, Plastics,Plastics Mold and tool Design, Composites (FRP), Engineering GraphicsMember of Various Editorial Board / reviewer : Springer, SME, etc.PG Thesis/ projects Guided: 10 
  • Hari Singh
  • Sona Rani
    Dr. Sona Rani has obtained her M.E (Software Engineering) degree from Thapar University (TIET), Patiala, and Ph.D from Kurukshetra University, Kurukshetrs. She is having more than 10 years of teaching Experience. She had guided more than 40 M.Tech Thesis/ Projects. Presently she is working with University Institute of Engineering and Technology, Kurukshetra University, Kurukshetra, Haryana, India.

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Publicado

2012-05-02

Edição

Vol. 2 N.º 1 (2012)

Secção

Research Articles

Licença

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