Electric Discharge Machining Lab Report
INTRODUCTION
Surface modification is a miraculous application of Electric Discharge Machining (EDM). It can modify the conductive material surface by both removing material from the surface and depositing material on the surface. It can remove or deposit material from the work surface through controlled electrical sparks by the process of melting and evaporation. The controlled sparks erode material from the work and tool surface within very short intervals of time. Study of surface morphology widens the application idea of the process. EDMed surface contains a white layer which crystallizes from molten liquid [1, 2]. Tool material is deposited by the re-solidification process at the base of craters, which is heavily alloyed by the interaction …show more content…
This condition does not correspond to anyone of the conducted L-16 experiments, but this optimum condition is similar as that for surface roughness and edge deviation. The given condition is a predicted optimum setting among the experiments only. Therefore, a confirmation experiment is needed to conduct at this condition, and the result is compared with the predicted value. A common confirmation experiment is carried out at the optimum condition with compact load of 20 ton, current of 3A and on-time of 463µs for the surface roughness, edge deviation and the OEC. The results are found as TWR of 8.9 mg/min, MTR of 4.98 mg/min, Ra of 4.6 µm, ED of 38.08 µm, and OEC value of …show more content…
However, those values decrease when OEC is considered with the given weightages as shown in Figure 6(a) and (b). Similarly, Ra and ED (with QC=Smaller) are higher when they are considered with 100% TWR and 100% MTR but those decrease whenever they are considered under OEC as shown in Figure 6(c) and (d).
The compact load of the P/M green tool material plays a significant role on TWR. The loose bonding eases to erode even at low energy and shorter pulse on-time. However, the erosion rate decreases with increased compaction load. Higher compaction load gives strong molecular bonding. Hence, higher energy is required to erode the tool material. The abrupt erosion of tool material at low compact load gives non-uniform material transfer thereby; very rough surface is obtained. However, finer surface is obtained at low TWR and MTR under higher compact
Surface modification is a miraculous application of Electric Discharge Machining (EDM). It can modify the conductive material surface by both removing material from the surface and depositing material on the surface. It can remove or deposit material from the work surface through controlled electrical sparks by the process of melting and evaporation. The controlled sparks erode material from the work and tool surface within very short intervals of time. Study of surface morphology widens the application idea of the process. EDMed surface contains a white layer which crystallizes from molten liquid [1, 2]. Tool material is deposited by the re-solidification process at the base of craters, which is heavily alloyed by the interaction …show more content…
This condition does not correspond to anyone of the conducted L-16 experiments, but this optimum condition is similar as that for surface roughness and edge deviation. The given condition is a predicted optimum setting among the experiments only. Therefore, a confirmation experiment is needed to conduct at this condition, and the result is compared with the predicted value. A common confirmation experiment is carried out at the optimum condition with compact load of 20 ton, current of 3A and on-time of 463µs for the surface roughness, edge deviation and the OEC. The results are found as TWR of 8.9 mg/min, MTR of 4.98 mg/min, Ra of 4.6 µm, ED of 38.08 µm, and OEC value of …show more content…
However, those values decrease when OEC is considered with the given weightages as shown in Figure 6(a) and (b). Similarly, Ra and ED (with QC=Smaller) are higher when they are considered with 100% TWR and 100% MTR but those decrease whenever they are considered under OEC as shown in Figure 6(c) and (d).
The compact load of the P/M green tool material plays a significant role on TWR. The loose bonding eases to erode even at low energy and shorter pulse on-time. However, the erosion rate decreases with increased compaction load. Higher compaction load gives strong molecular bonding. Hence, higher energy is required to erode the tool material. The abrupt erosion of tool material at low compact load gives non-uniform material transfer thereby; very rough surface is obtained. However, finer surface is obtained at low TWR and MTR under higher compact