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CAPSTONE PROJECT REPORT ON

STUDY THE PROCESS PARAMETERS OPTIMIZATION ON EN-31 USING EDM WITHOUT ABRASSIVE IN DILECTRIC FLUID

Mentor name-

JAIINDER PREET SINGH

SUBMITRD BY- GAURAV SHARMA(10803332)

COURSE:B.TECH(MECH) SECTION:RM18E1

DECLARATION I, GAURAV SHARMA, student of B.tech (ME) (Program name) under Department of ME of Lovely Professional University, Punjab, hereby declare that all the information furnished in this dissertation / capstone project report is based on our own intensive research and is genuine. This dissertation / report do not, to the best of my knowledge, contain part of my work which has been submitted for the award of my degree either of this university or any other university without proper citation.

Date: 26th Nov 11

Signature and Name of the student GAURAV SHARMA

Abstract In this paper, the effect of silicon powder mixing into the dielectric fluid of EDM on machining we will do machining with three different tool that is made of copper.aluminium and brass. Six process parameters namely peak current, pulse on time, pulse-off time, concentration of powder, gain, and nozzle flushing have been considered. The process performance is measured in terms of machining rate (MR). The research outcome will identify the important parameters and their effect on MR DIE STEEL in the presence and absence of suspended silicon powder in a kerosene dielectric of EDM. WE WILL IDENTIFY THE MATERIAL REMOVING RATE IN THE PRESENCE OF SLURRY AND IN THE ABSENCE AND ALSO WILL STUDY THE PROPERTIES OF ABRASSIVE LIKE 1. 2. 3. 4. 5. Material removing rate without abrasive in dielectric fluid Hardness of material(EN-31) after and before machining Graph between material removing rate (MRR) vs current intensity. Graph between tool wear and current intensity Surface roughness after machining with different tools material (cu,al,brass)

LITERATURE REVIEW In 1770, English physicist Joseph Priestley studied the erosive effect of electrical discharges. Furthering Priestley's research, the EDM process was invented by two Russian scientists, Dr. B. R. Lazarenko and Dr. N. I. Lazarenko, in 1943. In their efforts to exploit the destructive effects of an electrical discharge, they developed a controlled process for machining of metals. Their initial process used a spark machining process, named after the succession of sparks (electrical discharges) that took place between two electrical conductors immersed in a dielectric fluid. The discharge generator effect used by this machine, known as the Lazarenko circuit, was used for many years in the construction of generators for electrical discharge. Additional researchers entered the field and contributed many fundamental characteristics of the machining method we know today. In 1952, the manufacturer Charmilles created the first machine using the spark machining process and was presented for the first time at the European Machine Tool Exhibition in 1955. In 1969 Agie launched the world's first numerically controlled wire-cut EDM machine.Seibu developed the first CNC wire EDM machine 1972 and the first system manufactured in Japan.

TO STUDY THE PROCESS PARAMETERS OPTIMIZATION ON EN-31 USING EDM

Introduction
Electrical discharge machining (EDM) is one of the extensively used nonconventional material removal processes. It can be successfully employed to machine electrically conductive parts regardless of their hardness and toughness. In spite of remarkable process capabilities, limitations such as low volumetric material removal and poor surface quality are associated with EDM. In the recent past, powder mixed EDM (PMEDM) has emerged as one of the advanced techniques in the direction of the enhancement of the capabilities edm. material in fine powder form (aluminum, chromium,graphite, copper, or silicon carbide, etc.) is mixed into the dielectric fluid of EDM.

Principle of edm machine

Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called

the tool-electrode, or simply the tool or electrode, while the other is called the workpieceelectrode, or workpiece. When the distance between the two electrodes is reduced, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some point(s)), which breaks, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result, material is removed from both the electrodes. Once the current flow stops (or it is stopped depending on the type of generator), new liquid dielectric is usually conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried away and the insulating proprieties of the dielectric to be restored. Adding new liquid dielectric in the interelectrode volume is commonly referred to as flushing. Also, after a current flow, a difference of potential between the two electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur. The principle of PMEDM is. In this process, the material in powder form is mixed into the dielectric fluid either in the same tank or in a separate tank. When a voltage of 80-320 V is applied to both the electrodes, an electric field in the range 105 to 107 V/m is created. The spark gap is filled up with additive particles, and the gap distance between tool and the workpiece increases from 25 m to 50 m to many times larger . The powder particles get energized and behave in a zig-zag fashion.The grains come close to each other under the sparkingarea and gather in clusters. Under the influence ofelectric forces, the powder particles arrange themselves in the form of chains at different places under the sparking area . The chain formation helps in bridging the gap between both the electrodes. Due to the bridging effect, the gap voltage and insulating strength of the dielectric fluid decreases. The easy short-circuit takes place, which causes early explosion in the gap. As a result, the series discharge starts under the electrode area. Due to the increase in the frequency of discharging,the faster sparking within a discharge takes place, which causes faster erosion from the workpiece surface. At the same time, theadded powder modifies the plasma channel. The plasma channel gets enlarged . The electric density decreases; hence, sparking is uniformly distributed among the powder particles. As a result, even and more uniform distributionbof the discharge takes place, which causesbuniform erosion (shallow craters) on the workpiece.This results inimprovement in surface finish. The literature available on PMEDM is very limited. It can be easily observed from the available literature (presented in next section) that considerable efforts have been directed to improve the surface quality by suspending powder particles in the dielectric of EDM. However, very little work has been reported on the improvement of machining efficiency of PMEDM. The reduction of machining time especially for machining of some hard and tough materials like AISI D2 die steel with nonconventional machining processes is one of the most important requirements of modern industry. The major applications of AISI D2 steel are in the manufacturing of high-efficiency cutting tools (dies and punches) woodworking tools, shear blades for cutting thin materials, cold rolls for multiple roller stands, gauges, plastic molds, and so on. The aim of the present research work

was to set the optimum process parameters of the PMEDM process to maximize the MR of AISI D2 die steel. The MR is estimated by calculating the difference between the initial weight and the final weight of the workpiece after processing at a specified set of conditions by EDM or PMEDM as:

This is the formula to calculate material removing rate: Workpiece weight loss gm Density gm /mm Machining time min. mm / min.

DIELECTRIC FLUID :
The EDM setup consists of a power supply whose one lead is connected to the workpiece immersed in a tank having dielectric coil. The tank is connected to a pump, oil reservoir, and a filter system. The pump provides pressure for flushing the work area and moving the oil while the filter system removes and traps the debris in the oil. The oil reservoir restores the surplus oil and provides a container for draining the oil between the operations.

The main functions of the dielectric fluid are:

To flush the eroded particles produced during machining, from the discharge gap and remove the particles from the oil to pass through a filter system. To provide insulation in the gap between the electrode and the workpiece. To cool the section that was heated by the discharge machining.

The two most commonly used fluids are petroleum based hydrocarbon mineral oils and deionized water. The oils should have a high density and a high viscosity. These oils have the proper effects of concentrating the discharge channel and discharge energy but they might have a difficulty in flushing the discharge products.

For most EDM operations kerosene is the common die electric used with certain additives, that prevent gas bubbles and de-odoring. Silicon fluids and mixture of these fluids with petroleum oils have excellent results.

High removal rates, less tool wear, better surface finish have been obtained in the machining of titanium alloys. Other dielectric fluids with a varying degree of success include polar compounds such as aqueous solutions of ethylene glycol, water in emulsions and distilled water.

OBSERVATIONS OF EXPERIMENT 1
FOR EN31 For aluminium tool CURRENT = 2 AMPERE IMPRESSION= 1 mm=1000micron INITIAL WEIGHT OF (ALUMINIUM) TOOL= 17.7gram. FINAL WEIGHT OF TOOL= 17.7gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2832 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2831 gram TIME FOR MACHINING= 118 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) Since the aluminium is soft material for 2 ampere current it only left out the impression of 1000 microns above that the tools working gets stop. NOW, MRR = (2832-2831)GRAM/(118MIN)*(7.81(GRAM/CM^3)) MRR= 1.085MM^3/MINUTE

CALCULATIONS FOR TOOL WEAR

TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (17.7-17.7) = 0 gram

CALCULATIONS FOR TOOL WEAR

OBSERVATION 2 TOOL USED IS ALUMINIUM, MATERIAL USED IS EN31 CURRENT= 5 AMPERE MATERIAL REMOVED OR IMPRESSION LEFT ON WORK PIECE= 1mm INITIAL WEIGHT OF (ALUMINIUM) TOOL= 17.7gram. FINAL WEIGHT OF TOOL= 17.6gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2831 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2830gram TIME FOR MACHINING= 13.76 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) Since as we increase the current up 5 amperes the tool only goes upto 1000 micron NOW, MRR= (2831-2830)/ (13.76MIN)*(7.81(GRAM/CM^3)) MRR = 9.305 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (17.7-17.6) = 0.1 gram

CALCULATIONS FOR TOOL WEAR

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TOOL WEAR FOR ALUMINIUM TOOL GRAPH BETWEEN WEIGHT LOSS(TOOL WEAR VS CURRENT

OBSERVATION 3

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OBSERVATION 3
TOOL USED IS ALUMINIUM, MATERIAL USED IS EN31 CURRENT= 10 AMPERE MATERIAL REMOVED OR IMPRESSION LEFT ON WORK PIECE= 1mm INITIAL WEIGHT OF (ALUMINIUM) TOOL= 17.6gram. FINAL WEIGHT OF TOOL= 17.5gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2830 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2829gram TIME FOR MACHINING= 9.33 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) Since as we increase the current up 10 amperes the tool only goes upto 40 micron NOW, MRR= (2830-2829)/ (9.33MIN)*(7.81(GRAM/CM^3)) MRR = 13.726 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (17.6-17.5) = 0.1 gram\

OBSERVATION 3

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MATERIAL REMOVAL RATE FROM ALUMINIUM TOOL MATERIAL REMOVING RATE (MRR) VS CURRENT

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OBSERVATION 4

TOOL USED IS ALUMINIUM, MATERIAL USED IS EN31 CURRENT= 15 AMPERE MATERIAL REMOVED OR IMPRESSION LEFT ON WORK PIECE= 1mm INITIAL WEIGHT OF (ALUMINIUM) TOOL= 17.5gram. FINAL WEIGHT OF TOOL= 17.4gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2829 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2828gram TIME FOR MACHINING= 6.25 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) Since as we increase the current up 15 amperes the tool only goes upto 40 micron NOW, MRR= (2829-2828)/ (6.25MIN)*(7.81(GRAM/CM^3)) MRR = 19.97 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (17.6-17.5) = 0.1 gram

OBSERVATION 5

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OBSERVATION 5

FOR COPPER TOOL FOR EN31 CURRENT = 2 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 41gram. FINAL WEIGHT OF TOOL= 40.8gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2836 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2835gram TIME FOR MACHINING= 110minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2386-2385)GRAM/(110MIN)*(7.81(GRAM/CM^3)) MRR = 1.16 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (41-40.8) = 0.2 gram

TOOL WEAR OF COPPER TOOL

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TOOL WEAR OF COPPER TOOL

GRAPH IN TOOL WEAR VS CURRENT

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OBSERVATION 6
FOR COPPER TOOL FOR EN31 CURRENT = 5 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 40.8gram. FINAL WEIGHT OF TOOL= 40.7gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2835 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2834gram TIME FOR MACHINING= 12.83minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2385-2384)GRAM/(12.83MIN)*(7.81(GRAM/CM^3)) MRR = 9.970 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (40.8 -40.7) = 0.1 gram It is observed from experiment 6 that the machining time increases (for a constant depth of cut of 1mm)As compared to observation 5 and the tool wear also reduces by reducing the intensity of applied current

OBSERVATION 6

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MATERIAL REMOVING RATE BY COPPER TOOL GRAPH : MRR(MATERIAL REMOVAL RATE VS CURRENT

OBSERVATION 6

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OBSERVATION 7
FOR COPPER TOOL FOR EN31 CURRENT = 10 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 40.7gram. FINAL WEIGHT OF TOOL= 40.5gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2834 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2833gram TIME FOR MACHINING= 8.31minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2384-2383)GRAM/(8.31MIN)*(7.81(GRAM/CM^3)) MRR = 15.396 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (40.7 -40.5) = 0.2 gram Since the material removal rate in this case is maximum and the machining time is minimum . there is a difference of 0.2 mm of the weight of tool in observation 6 and 7 this is because after performing the experiment at 10 ampere the carbon get liberated in between the tool and the work piece and it gets attached so it stops the working of tool so carbon gets removed by rubbing it on the amery paper so the tool looses the weight of 0.2 gram after rubbing.

OBSERVATION 6

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OBSERVATION 8
FOR COPPER TOOL FOR EN31 CURRENT = 15 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 40.5gram. FINAL WEIGHT OF TOOL= 40.4gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2833 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2832gram TIME FOR MACHINING= 5.082minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2383-2382)GRAM/(5.082MIN)*(7.81(GRAM/CM^3)) MRR = 25.20 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (40.5 -40.4) = 0.1 gram

OBSERVATION 6

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OBSERVATION 9
FOR BRASS TOOL FOR EN31 CURRENT = 2 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 35gram. FINAL WEIGHT OF TOOL= 34.9gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2828 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2827gram TIME FOR MACHINING= 114 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2828-2827)GRAM/(114MIN)*(7.81(GRAM/CM^3)) MRR = 1.123 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (35 -34.9) = 0.1 gram

OBSERVATION 6

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TOOL WEAR OF BRASS TOOL GRAPH : TOOL WEAR VS CURRENT

OBSERVATION 6

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OBSERVATION 10
FOR BRASS TOOL FOR EN31 CURRENT = 5 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 34.9gram. FINAL WEIGHT OF TOOL= 34.8gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2827 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2826gram TIME FOR MACHINING= 13.16 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2828-2827)GRAM/(13.16MIN)*(7.81(GRAM/CM^3)) MRR = 9.73 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (34.9 -34.8) = 0.1 gram

OBSERVATION 6

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MATERIAL REMOVAL RATE BY BRASS TOOL GRAPH: MRR(MATERIAL REMOVAL RATE ) VS CURRENT

OBSERVATION 6

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OBSERVATION 11
FOR BRASS TOOL FOR EN31 CURRENT = 10 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 34.8gram. FINAL WEIGHT OF TOOL= 34.6gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2826 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2825gram TIME FOR MACHINING= 8.83 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2826-2825)GRAM/(8.83MIN)*(7.81(GRAM/CM^3)) MRR = 14.501 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (34.8 -34.6) = 0.1 gram

OBSERVATION 6

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OBSERVATION 12
FOR BRASS TOOL FOR EN31 CURRENT = 15 AMPERE IMPRESSION= 1 MM INITIAL WEIGHT OF (COPPER) TOOL= 34.6gram. FINAL WEIGHT OF TOOL= 34.5gram. INITIAL WEIGHT OF WORK PIECE (EN31) = 2825 gram FINAL WEIGHT OF WORK PIECE (EN31) = 2824gram TIME FOR MACHINING= 5.75 minutes METARIAL REMOVAL RATE (MRR)= (LOSS OF WEIGHT)/(DENSITY OF WORK PIECE)*(MACHINING TIME) MRR = (2825-2824)GRAM/(5.75MIN)*(7.81(GRAM/CM^3)) MRR = 22.268 MM^3/MINUTE CALCULATIONS FOR TOOL WEAR TOOL WEAR= (INITIAL WEIGHT OF TOOL-FINAL WEIGHT OF TOOL) TOOL WEAR= (34.6 -34.5) = 0.1 gram

OBSERVATION TABLE
For work piece material EN31 and tool material is aluminium . Tool Material Material removal rate(y-axis) (in mm^3/min.) Aluminium Aluminium 1.085 9.305 Current intensity (X-axis) (in ampere) 2 5

OBSERVATION 6

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aluminium

13.726

10

aluminium

19.97

15

For work piece material EN31 and tool material is copper. Tool Material Material removal rate(y-axis) (in mm^3/min.) copper copper copper 1.16 9.979 15.396 Current intensity (X-axis) (in ampere) 2 5 10

copper

25.20

15

For work piece material EN31 and tool material is brass. Tool Material Material removal rate(y-axis) (in mm^3/min.) brass brass brass 1.123 9.73 14.501 Current intensity (X-axis) (in ampere) 2 5 10

brass

22.268

15

OBSERVATION 6

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HARDNESS OF MATERIAL AFTER AND BEFORE MACHINING BEFORE MACHINING 111 HRB(ROCKWELL HARDNESS B-SCALE) AFTER MACHINING 103.5 HRB(ROCKWELL HARDNESS B-SCALE

OBSERVATION 6

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This is the 12 holes we machined on edm machine on different values of current and with three different tool copper,aluminium and brass

OBSERVATION 6

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Conclusions
Electric discharge machining (EDM) has been found to be a promising machining technique for obtaining desired dimensional accuracy and intricacy from hard and tough die steels like high carbon high chrome materials. Powder mixing into the dielectric fluid of EDM is one of the innovative developments that ensures better machining rates at desired surface quality. The result of the present work identifies the significant process parameters and optimizes the machining conditions in the presence of silicon powder in the dielectric fluid to get maximum machining rate from AISI D2 die steel. Within the range of parameters selected for the present work, the following conclusions are drawn: 1. Higher the current value increases the material removing rate but decreases the surface finish

2. hardness of workpiece after material decreases around and on the place where machining has been done. 3. the machined surface losses its ductility and brittlness increased. 4. the material from tool also losses during machining ,as the value of current imcreases the tool wear also increases. 5. Surface roughness increases if the machining has been done on high current or vice versa.

OBSERVATION 6

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