CHAPTER-1

INTRODUCTION

1.1 Introduction of EDM

The history of EDM Machining Techniques goes as far back as the 1770s when it was
discovered by an English Scientist. However, Electrical Discharge Machining was not fully taken
advantage of until 1943 when Russian scientists learned how the erosive effects of the
technique could be controlled and used for machining purposes.

When it was originally observed by Joseph Priestly in 1770, EDM Machining was very
imprecise and riddled with failures. Commercially developed in the mid1970s, EDM began to be
a viable technique that helped shape the metal working industry we see today. In the
mid1980s.The EDM techniques were transferred to a machine tool. This migration made
EDM more widely available and appealing over traditional machining processes.

The new concept of manufacturing uses non-conventional energy sources like sound, light,
mechanical, chemical, electrical, electrons and ions. With the industrial and technological growth,
development of harder and difficult to machine materials, which find wide application in
aerospace, nuclear engineering and other industries owing to their high strength to weight
ratio, hardness and heat resistance qualities has been witnessed. New developments in the field
of material science have led to new engineering metallic materials, composite materials and high
tech ceramics having good mechanical properties and thermal characteristics as well as sufficient
electrical conductivity so that they can readily be machined by spark erosion. Non-traditional
machining has grown out of the need to machine these exotic materials. The machining
processes are non-traditional in the sense that they do not employ traditional tools for metal
removal and instead they directly use other forms of energy. The problems of high complexity
in shape, size and higher demand for product accuracy and surface finish can be solved
through non-traditional.

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 Capabilities except for volumetric material removal rates, for which great advances have been
made in the past few years to increase the material removal rates. As removal rate increases, the
cost effectiveness of operations also increase, stimulating ever greater uses of nontraditional
process. The Electrical Discharge Machining process is employed widely for making tools, dies
and other precision parts.

EDM has been replacing drilling, milling, grinding and other traditional machining
operations and is now a well-established machining option in many manufacturing industries
throughout the world. And is capable of machining geometrically complex or hard material
components, that are precise and difficult-to-machine such as heat treated Die Steels, composites,
super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making
industries, aerospace, aeronautics and nuclear industries. Electric Discharge Machining has also
made its presence felt in the new fields such as sports, medical and surgical, instruments,
optical, including automotive R&D areas.

1.2 Introduction OF EDM

Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining

Process, where electrical energy is used to generate electrical spark and material removal
mainly occurs due to thermal energy of the spark.
EDM is mainly used to machine difficult-to-machine materials and high strength
temperature resistant alloys. EDM can be used to machine difficult geometries in small batches
or even on job-shop basis. Work material to be machined by EDM has to be electrically
conductive.
1.3 Working Principle:

In this process the metal is removing from the work piece due to erosion case by rapidly
recurring spark discharge taking place between the tool and work piece. Show the mechanical
set up and electrical set up and electrical circuit for electro discharge machining. A thin gap
about 0.025mm is maintained between the tool and work piece by a servo system shown in fig
1.3.1. Bothtoolandworkpiecearesubmergedinadielectricfluid.Kerosene/EDMoil/deionized water is
very common type of liquid dielectric although gaseous dielectrics are also used in certain cases.

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Fig1.3.1: Set up of Electric discharge machining

This fig.1.3.1 is shown the electric setup of the Electric discharge machining. The tool
is mead cathode and work piece is anode. When the voltage across the gap becomes
sufficiently high it discharges through the gap in the form of the spark in interval of from 10 of
micro seconds. And positive ions and electrons are accelerated, producing a discharge
channel that becomes conductive. It is just at this point when the spark jumps causing
collisions between ions and electrons and creating a channel of plasma. A sudden drop of the
electric resistance of the previous channel allows that current density reaches very high values
producing an increase of ionization and the creation of a powerful magnetic field. The
moment spark occurs sufficiently pressure developed between work and tool as a result of
which a very high temperature is reached and at such high pressure and temperature that some
metal is melted and eroded.
Such localized extreme rise in temperature leads to material removal. Material
removal occurs due to instant vaporization of the material as well as due to melting. The molten
metal is not removed completely but only partially

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As the potential difference is withdrawn as shown in Fig. 1.3.2, the plasma channel is no
longer sustained. As the plasma channel collapse, it generates pressure or shock waves,
which evacuatesthemoltenmaterialformingacraterofremovedmaterialaroundthesiteofthespark.

Fig1.3. 2 Working principle of EDM process

1.4 Mechanism of MRR:

The mechanism of material removal of most widely established EDM process is the
conversion of electrical energy it into thermal energy. During the process of machining the
sparks are produced between work piece and tool. Thus each spark produces a tiny crater, and
crater formation shown in the Figure-1.4.1 in the material along the cutting path by melting
and vaporization, thus eroding the work piece to the shape of the tool. It is well-known and
elucidated by many EDM researchers that Material Removal Mechanism (MRM) is the
process of transformation of material elements between the work-piece and electrode. The
transformation are transported in solid, liquid or gaseous state, and then alloyed with the
contacting surface by undergoing a solid, liquid or gaseous phase reaction.

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Fig 1.4.1: Mechanism of MRR

1.5 Types of EDM:
Basically, there are two different types of EDM:

1.Die-sinking EDM
2.Wire-cut EDM

1.5.1 Die-sinking EDM

In the Sinker EDM Machining process, two metal parts submerged in an insulating liquid are
connected to a source of current which is switched on and off automatically depending on the
parameters set on the controller. When the current is switched on, an electric tension is created
between the two metal parts. If the two parts are brought together to within a fraction of an inch,
the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated
up so much that it melts. Sinker EDM, also called cavity type EDM or volume EDM consists of
an electrode and work piece submerged in an insulating liquid such as, more typically, oil or, less
frequently, other dielectric fluids. The electrode and work piece are connected to a suitable power
supply. The power supply generates an electrical potential between the two parts. As the
electrode approaches the work piece, dielectric breakdown occurs in the fluid, forming a plasma
channel, and a small spark jumps these sparks usually strike one at a time because it is very
unlikely that different locations in the inter-electrode space have the identical local electrical
characteristics which would enable a spark to occur simultaneously in all such locations. These
sparks happen in huge numbers at seemingly random locations between the electrode and the
work piece. As the base metal is eroded, and the spark gap subsequently increased, the electrode
is lowered automatically by the machine so that the process can continue uninterrupted. Several
hundred thousand sparks occur per second, with the actual duty cycle carefully controlled
by the setup parameters.

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1.5.2 Wire-cut EDM

Wire EDM Machining (also known as Spark EDM) is an electro thermal production
process in which a thin single-strand metal wire (usually brass) in conjunction with de-ionized
water (used to conduct electricity) allows the wire to cut through metal by the use of heat
from electrical sparks. A thin single-strand metal wire, usually brass, is fed through the work
piece, submerged in a tank of dielectric fluid, typically deionizer water. Wire-cut EDM is
typically used to cut plates as thick as 300mm and to make punches, tools, and dies from
hard metals that are difficult to machine with other methods. Wire-cutting EDM is
commonly used when low residual stresses are desired, because it does not require high
cutting forces for removal of material. If the energy/power per pulse is relatively low (as
in finishing operations), little change in the mechanical properties of a material is
expected due to these low residual stresses, although material that hasn't been stress-relieved
can distort in the machining process. Due to the inherent properties of the process, wire EDM
can easily machine complex parts and precision components out of hard conductive materials.

Fig 1.5.1: Die sinking & wire cut EDM Process

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1.6 Important parameters of EDM

a) Spark On-time (pulse time or Ton): The duration of time (µ s) the current is allowed
to flow per cycle. Material removal is directly proportional to the amount of energy
applied during this on-time. This energy is really controlled by the peak current and the
length of then-time.
b) Spark Off-time (pause time or Toff): The duration of time (µ s) between the sparks
(that is to say, on-time). This time allows the molten material to solidify and to be wash
out of the arc gap. This parameter is to affect the speed and the stability of the cut.

c) Arc gap (or gap): The Arc gap is distance between the electrode and work piece
during the process of EDM. It may be called as spark gap. Spark gap can be maintained
by servo system
d) Discharge current (current Ip): Current is measured in amp Allowed to per cycle.
Discharge current is directly proportional to the Material removal rate.
e) Duty cycle (τ): It is a percentage of the on-time relative to the total cycle time. This
parameter is calculated by dividing the on-time by the total cycle time (on-time pulse
off- time) τ = T on/( Ton=Toff)

f) Voltage (V): It is a potential that can be measure by volt it is also effect to the material
removal rate and allowed to per cycle. Voltage is given by in this experiment is 50.

g) Diameter of electrode (D): It is the electrode of Cu-tube there are two different size of
diameter 4mm and 6mm in this experiment. This tool is used not only as an electrode
but also for internal flushing.

h) Over cut – It is a clearance per side between the electrode and the work piece after
the machine operation.

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1.7 Characteristics of EDM

EDM specification by mechanism of process, metal removal rate and other
function that shown in this table 1
Table1: Specification on EDM

Mechanism of process Controlled erosion (melting and evaporation) through a series

of electric spark

Sparkgap 0.010- 0.500 mm

Spark frequency 200 – 500 kHz

Peak voltage across the gap 30- 250 V

Metal removal rate (max.) 5000 mm3/min

Specific power 2-10 W/mm3/min

consumption
Dielectric fluid EDM oil, Kerosene liquid paraffin, silicon oil, de ionized
water etc.

Tool material Copper, graphite.

MRR /E W R 0.1-10

Materials that can be All conducting metals and alloys.

machined
Shapes Micro holes, narrow slots, blind cavities

Limitations High specific energy consumption, on conducting

Materials can’t be machined.
1.8 Dielectric fluid
In EDM, as has been discussed earlier, material removal mainly occurs due to thermal
evaporation and melting. As thermal processing is required to be carried out in absence
of oxygen so that the process can be controlled and oxidation avoided. Oxidation often leads
to poor surface conductivity (electrical) of the work piece hindering further machining.
Hence, dielectric fluid should provide an oxygen free machining environment. Further it
should have enough strong dielectric resistance so that it does not breakdown electrically too
easily but at the same time ionize when electrons collide with its molecules.
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The dielectric fluid has the following functions:

 It helps in initiating discharge by serving as a conducting medium when ionized, and
conveys the spark. It concentrates the energy to a very narrow region.
 It helps in quenching the spark, cooling the work, tool electrode and enables arcing to
be prevented.
 It carries away the eroded metal along with it.
 It acts as a coolant in quenching the sparks.
The electrode wear rate, metal removal rate and other operation characteristics are also
influenced by the dielectric fluid.
The dielectric generally fluid used are transformer on silicon oil, EDM oil, kerosene
(paraffin oil) and de-ionized water are used as dielectric fluid in EDM. Tap water cannot be
used as it ionizes too early and thus breakdown due to presence of salts as impurities occur.
Dielectric medium is generally flushed around the spark zone. It is also applied through the
tool to achieve efficient removal of molten material.
In this experiment using the Commercial grade EDM oil (specific gravity= 0.763, freezing
point= 94˚C) was used as dielectric fluid are used it is using as coolant and medium of work
piece and tool during the process of erosion.

1.9 Tool Material

Tool material should be such that it would not undergo much Electrode Wear when it is
impinged by positive ions. Thus the localized temperature rise has to be less by tailoring or properly
choosing its properties or even when temperature increases, there would be less melting.
Further, the tool should be easily workable as intricate shaped geometric features are machined in
EDM.

Thus the basic characteristics of electrode materials are:

 High electrical conductivity – electrons are cold emitted more easily and there is less
bulk electrical heating.
 High thermal conductivity – for the same heat load, the local temperature rise would be
less due to faster heat conducted to the bulk of the tool and thus less Electrode Wear.
 Higher density – for the same heat load and same Electrode Wear by weight there
would be less volume removal or Electrode Wear and thus less dimensional loss .

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 High melting point – high melting point leads to fewer tools wear due to less tool
material melting for the same heat load.
 Easy manufacturability
 cheap cost

The followings are the different electrode materials which are used commonly in the
industry:
1. Graphite
2. Copper
In this experiment are using the Cu tool circular shaped tool with internal flushing
system this tool material can be eroded by circular shaped.

1.9.1 Design variable

Design parameter, process parameter and constant parameter are following ones,

Design parameters

1. Material removal rate.

2. Electrode Wear rate

3. Surface roughness

4. Spark gap

Machining parameter

1. Discharge current(Ip)
2. Pulse on time(Ton)

3. Pulse off time(T off )

4. Voltage

5. Diameter of circular shaped tool

Tool Constant parameter

1. Duty cycle
2. Flushing pressure
3. Polarity

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1.10 Work piece material

It is capable of machining geometrically complex or hard material components,

that are precise and difficult-to-machine such as heat treated Die Steels, composites, super
alloys, ceramics, carbides, heat resistant steeled.

There are different types of tool material are using the EDM method. And the Die
Steel contains carbon and alloy steels that are particularly well-suited to be made into
tools. Their suitability comes from their distinctive hardness, resistance to abrasion, their
ability to hold a cutting edge, and/or their resistance to deformation at elevated
temperatures (red-hardness). Die Steel is generally used in a heat-treated state. Die Steels
are made to a number of grades for different applications. In general, the edge
temperature under expected use is an important determinant of both composition and
required heat treatment. The higher carbon grades are typically used for such applications as
stamping dies, metal cutting tools, etc.

1.11 Application of EDM

 The EDM process is most widely used by the mould-making tool and die industries, but is
becoming a common method of making prototype and production parts, especially in the
aerospace, automobile and electronics industries in which production quantities are relatively
low.
 It is used to machine extremely hard materials that are difficult to machine like alloys, Die
Steels, and tungsten carbidesetc.
 It is used for forging, extrusion, wire drawing, thread cutting.
 It is used for drilling of curved holes.
 It is used for internal thread cutting and helical gear cutting.
 It is used for machining sharp edges and corners that cannot be machined effectively by
other machining processes.

 Higher Tolerance limits can be obtained in EDM machining. Hence areas that require

higher surface accuracy use the EDM machining process.

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1.12 Advantages of EDM

 Any material that is electrically conductive can be cut using the EDM process.

 Hardened work pieces can be machined eliminating the deformation caused by heat treatment.

 X, Y, and Z axes movements allow for the programming of complex profiles using
simple electrode.
 Complex dies sections and molds can be produced accurately, faster, and at lower
costs. Due to the modern NC control systems on die sinking machines, even more
complicated work pieces can be machined.
 The high degree of automation and the use of tool and work piece changers allow the
machines to work unattended for overnight or during the weekends
 Forces are produced by the EDM-process and that, as already mentioned, flushing and
hydraulic forces may become large for some work piece geometry. The large cutting forces
of the mechanical materials removal processes, however, remain absent.
 Thin fragile sections such as webs or fins can be easily machined without deforming the part

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1.13 Limitations of EDM

 The need for electrical conductivity – To be able to create discharges, the work piece has
to be electrically conductive. Isolators, like plastics, glass and most ceramics, cannot be
machined by EDM, although some exception like for example diamond is known.

 Conductors like Si semi-conductors, partially conductive ceramics and even glass is also
possible.

 Predictability of the gap - The dimensions of the gap are not always easily predictable,
especially with intricate work piece geometry. In these cases, the flushing conditions and the
contamination state of differ from the specified one. In the case of die-sinking EDM, the
Electrode Wear also contributes to a deviation of the desired work piece geometry and it
could reduce the achievable accuracy. Intermediate measuring of the work piece or some
preliminary tests can often solve the problems.
 Low material removal rate- The material removal of the EDM-process is rather low,
especially in the case of die-sinking EDM where the total volume of a cavity has to be
removed by melting and evaporating the metal. With wire-EDM only the outline of the
desired work piece shape has to be machined. Due to the low material removal rate, EDM is
principally limited to the production of small series although some specific mass production
applications are known.

 Optimization of the electrical parameters - The choice of the electrical parameters of the EDM-
process depends largely on the material combination of electrode and work piece and EDM
manufactures only supply these parameters for a limited amount of material
o combinations. When machining special alloys, the user has to develop hewn technology.

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CHAPTER-2
LITERATURE SURVEY

In this chapter search few selected research paper related to EDM with effect of
metal MRR, EWR, OC, surface roughness (SR) work piece material, we are broadly classified
all the project in to three different category, i.e. project related to material related work piece
or tool, circular electrode and optimization of parameters.

LITERATURES:
S. Rajesha et.al[1]: Electro discharge machining is a nonconventional machining process
extensively used in industry for processing of parts having unusual profiles with reasonable
precision.
S. R. Nimbhorkar et.al[2]:Steel is a widely used engineering material. There are a
variety of steels used for numerous applications. The steel is being divided into low carbon,
medium carbon, and high carbon steel on the basis of carbon content. Low carbon steel contains
carbon content from 0.15% to 0.45%. It is the most common form of steel as it provides material
properties that are acceptable for many applications
A. Bensely et.al[3]: EN 353 steel is cheaply available and widely used alloy. EN 353
is low alloy case car-buried steel, predominantly used for manufacturing heavy-duty gears,
shafts, pinions, and especially crown wheel
S. Murugesan et.al[4]: Discharge current was the most significant controlling parameter in
machining Al-15% SiC MMC using multi-hole electrode by grey relational analysis, while
Taguchi method was employed to determine the relations between the machining parameters and
process characteristics like MRR (material removal rate), EWR (electrode wear rate), and SR
(surface roughness)
Singh et.al[5]:The combination of maximum pulse on time and minimum pulse of f time
gives maximum MRR on Al-7075 alloy with brass electrode using Taguchi approach
F. L. Amorim et.al[6]:Amorim and Weingaertner concluded that the best results of MRR
and surface texture for duty factor of 0.5 were obtained with tungsten-copper electrodes, no matter
the machining conditions while machining copper-beryllium ASTM C17200 alloy

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O. Yilmaz et.al[7]:Single-channel electrodes have comparatively better MRR and lower

EW during fast whole drilling of Inconel 718 and Ti-6Al-4V with tubular electrodes of brass and
copper, while copper electrode undergoes lower wear than brass electrode
R. Manikandan et.al[8]:Discharge current, pulse on time and pulse of f time, had a
significant influence on the machining characteristics such as MRR, EWR, and overcut while
machining Inconel 718
G. Kibria et.al[9]:on gap current while machining high strength low alloy steel
(HSLA), respectively.
N. Sharma et.a[10]: Kerosene decomposes at higher temperature due to larger discharge
energy and produces carbon particles that adhere to the electrode surface and this
phenomenon restricts rapid Electrode Wear during machining than deionized water
M. S. Azad et.al[11]: Globules of debris, pockmarks, and melted drops were observed on
the surfaces of blind holes which were more dispersed and pronounced. Most significant
parameters like voltage and current in the optimization of a single quality characteristic are not
being significant as in multiple quality characteristics
A. D. Patel et.al[12]: Patel et al. done the multi objective optimization with copper electrode
and concluded that lower value of parameters reduces the Electrode Wear ratio substantially,
while their higher values increase the MRR drastically on AISI Die Steel
P. Janmanee et.al[13]: MRR not only increases with increase in discharge cur-rent but
also increases the microcracks density on machining tungsten carbide with graphite electrode
M. Boujelbene et.al[14]:Increasing discharge energy increases instability and, due to
which, the quality of the work piece surface becomes rougher and the white layer thickness
increases. Also the amount of particles in the gap becomes too large and forms electrically
con-ducting paths between the tool electrode and the work piece causing unwanted discharges,
which becoming electric arcs (arcing). These electric arcs damage the electrodes surfaces (tool
and work piece surfaces) and can create micro cracks.
A.K.Khanraet.al[15]: During EDM processes, a significant amount of work-piece material
was found to be transferred from workpiece surface to tool surface and vice versa. Also, a
continuous burning of cutting fluid gives out a carbon residue, a visual black layer on machined
surface, which decreases the EWR.
H.K.Kansalet.al[16]:The surface roughness of EN-31 Die Steel with copper electrode
gives the best surface finish if obtained at the lower level of peak current and pulse on time.
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T.C.TOY et al[17]:While increasing the pulse current or reducing the pulse on

duration suppresses the formation of surface cracks in the SKD11 machined surface and hence
improves the fatigue life
A.Kumaret.al[18]: revealed that intense heat conditions in the machining zone yielded
higher crack densities and surface roughness while machining titanium at higher peak current
along with a higher frequency of the globules of debris than on steel.
A. T. Bozdana et.al[19]:Mathematical modeling of process using response surface
methodology shows that the developed model can achieve reliable prediction of experimental
results within acceptable accuracy
C Aydas¸ and Hasc¸alik et.al[20]:The RSM is an economical way for obtaining
information for any system with the fewest numbers of experiments.
D. C. Whittinghill et.al[21]:Box-Behnken design gives us robustness to the
unavailability of data over central composite design
K.Ojha&R.K.Garg et al[22]:Reversing the polarity of sparking alters the material
removal phenomenon with an appreciable amount of electrode material depositing on the
workpiece surface.
N.Kumar et al[23]:Due to its structural integrity, copper has ability to produce very fine
surface finishes, even without special polishing circuits. It also makes copper electrodes highly
resistant to DC arcing in poor flushing situation.

Objective of the present work:

From the research papers in this classification, it is observed that few works has
been reported on EDM on the material Al-Sic, EN-19, SKH 57, AISI H13, AISI D2 Die
Steel, and various composite materials. Study on EDM of different material and different
mathematical model can be use to validated the experimental results.
The objective of the present work is an attempt to finding feasibility of machining M2
Die Steel using Circular shaped copper & graphite electrode and internal flushing. The
machining parameter selected for discharge current, pulse on time, and diameter of the tool using
design Origin approach analyzing the responses MRR, EWR, and Surface Roughness.

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CHAPTER-3
METHODS AND METHODOLOGY
3.1 OPTIMIZATION-Introduction
Optimization is the process of finding the greatest or least value of a function for
some constraint, which must be true regardless of the solution. In other words,
optimization finds the most suitable value for a function within a given domain.
The purpose of optimization is to achieve the “best” design relative to a set of
prioritized criteria or constraints. These include maximizing parameters such as discharge
current, EWR, MRR, OC and Surface Roughness.
3.2 Optimization Techniques-Taguchi Method
3.2.1 Introduction:
Taguchi method is a statistical method developed by Taguchi and Konishi Initially it was
developed for improving the quality of goods manufactured (manufacturing process
development), later its application was expanded to many other fields in Engineering, such as
Biotechnology etc. Professional statisticians have acknowledged Taguchi’s efforts especial y in
the development of designs for studying variation. Success in achieving the desired results
involves a careful selection of process parameters and bifurcating them into control and noise
factors. Selection of control factors must be made such that it nullifies the effect of noise factors.
Taguchi Method involves identification of proper control factors to obtain the optimum results
of the process. Orthogonal Arrays (OA) are used to conduct a set of experiments. Results of
these experiments are used to analyze the data and predict the quality of components produced.
Here, an attempt has been made to demonstrate the application of Taguchi’s Method to
improve the surface finish characteristics of faced components that were processed on a lathe
machine. Surface roughness is a measure of the smoothness of a products surface and it is a
factor that has a high influence on the manufacturing cost. Surface finish also affects the life of
any product and hence it is desirable to obtain higher grades of surface finish at minimum
cost.

3.2.2Approach to Product/Process Development

Many methods have been developed and implemented over the years to optimize the
manufacturing processes. Some of the widely used approaches are as given below:

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(a )Build-Test-Fix
The “Build-test-fix” is the most primitive approach which is rather inaccurate as the
process is carried out according to the resources available, instead of trying to optimize it. In this
method the process/product is tested and reworked each time till the results are acceptable. (b) One
Factor at a Time
The “one-factor-at-a-time” approach is aimed at optimizing the process by running an experiment
at one particular condition and repeating the experiment by changing any other one factor till the
effect of all factors are recorded and analyzed. Evidently, it is a very time consuming and
expensive approach. In this process, interactions between factors are not taken in to account.
(c) Design of Experiments
The Design of Experiments is considered as one of the most comprehensive approach in
product/process developments. It is a statistical approach that attempts to provide a predictive
knowledge of a complex, multi-variable process with few trials. Following are the major
approaches to DOE:
 Full Factorial Design A full factorial experiment is an experiment whose design consists of
two or more factors, each with a discrete possible level and whose experimental units take
all possible combinations of all those levels across all such factors. Such an experiment
allows studying the effect of each factor on the response variable, as well as on the effects of
interactions between factors on the response variable. A common experimental design is the
one with all input factors set at two levels each. If there are k factors each at 2 levels; a full
factorial design has 2 k runs. Thus for 6 factors at two levels it would take 64 trial runs.

 Taguchi Method The Full Factorial Design requires a large number of experiments to be
carried out as stated above. It becomes laborious and complex, if the number of factors
increase. To overcome this problem Taguchi suggested a specially designed method called
the use of orthogonal array to study the entire parameter space with lesser number of
experiments to be conducted. Taguchi thus, recommends the use of the loss function to
measure the performance characteristics that are deviating from the desired target value. The
value of this loss function is further transformed into signal-to-noise (S/N) ratio. Usually,
there are three categories of the performance characteristics to analyze the S/N ratio. They
are: nominal-the-best, larger-the-better, and smaller-the-better.

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3.2.3Steps Involved in Taguchi Method:

The use of Taguchi’s parameter design involves the following steps .
a. Identify the main function and its side effects.
b. Identify the noise factors, testing condition and quality characteristics.
c. Identify the objective function to be optimized.
d. Identify the control factors and their levels.
e. Select a suitable Orthogonal Array and construct the Matrix
f. Conduct the Matrix experiment.
g. Examine the data; predict the optimum control factor levels and its performance.
h. Conduct the verification experiment.
3.3 Optimization Techniques-ANOVA METHOD:
Analysis of variance (ANOVA) is a statistical procedure concerned with comparing means
of several samples. It can be thought of as an extension of the t-test for two independent
samples to more than two groups. The purpose is to test for significant differences between
class means, and this is done by analysis the variances.
The ANOVA test of the hypothesis is based on a comparison of two independent estimates of
the population variance . When performing an ANOVA procedure the following assumptions
are required:
 The observations are independent of one another.
 The observations in each group come from a normal distribution.
 The population variances in each group are the same (homoscedasticity
ANOVA is the most commonly quoted advanced research method in the professional business
and economic literature. This technique is very useful in revealing important information particularly
in interpreting experimental outcomes and in determining the influence of some factors on
other processing parameters. The original ideas of analysis of variance were developed by the
English statistician Sir Ronald A. Fisher (1890-1962) in his book “Statistical Methods for
Research Workers” (1925). Much of the early work in this area dealt with agricultural
experiments).

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3.4 Optimization Techniques -GREY RELATIONAL ANALYSIS

Grey Relational Analyses are applied to determine the suitable selection of machining
parameters for Electrical Discharge Machining (EDM) process. The Grey theory can provide a
solution of a system in which the model is unsure or the information is incomplete. Besides,
it provides an efficient solution to the uncertainty, multi-input and discrete data problem.
According to the Taguchi quality design concept,aL32mixedorthogonal-array table
waschosen forthe experiments. With both Grey relational analysis and statistical method, it is
found that the table-feed rate has a significant influence on the machining speed, whilst the
gap width and the surface roughness are mainly influenced by pulse-on time. Moreover, the
optimal machining parameters setting for maximum machining speed and minimum surface
roughness (or a desired surface roughness) can be obtained. The relationship between
various factors mentioned in the previous section is unclear. Such systems are called GREY,
implying poor incomplete and uncertain information. Their analysis by standard statistical procedure
may not be acceptable or reliable without large data sets. In this work, Grey Relational Analysis
(GRA) has been used to convert the multi-response optimization model into a single response grey
relational grade. Instead of using experimental values directly in multiple regression model and GA,
grades are used to study about multi-response characteristics.

3.4.1Steps in GRA:

The following steps to be followed while applying grey relational analysis to find the Grey
relational coefficients and the grey relational grade:
1.Normalizing the experimental results of MRR and surface roughness to avoid the effect of
adopting different units to reduce the variability.

Zij= (1)

Zij =

2.Performing the grey relational generating and calculating the grey.

Co-efficient for the normalized values yield. (3)

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3.Calculating the grey relational grade by averaging the grey relational coefficient yields:

Where j is the grey relational grade for the jth experiment

and k is the number of performance characteristics.
Equation (1) is used to normalize the experimental value
characteristic of the original sequence, then the original sequence is normalized using

When the target of the original value is having the characteristics of higher the better.
Here MRR is normalized using the above equation, When the lower the better
Equation (2), i.e., surface roughness is normalized using this equation. Using Equation (3),
. Also the grey relational grade is computed as per Equation (4).

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CHAPTER-4
EXPERIMENTAL WORK

4.1.1 Introduction

In this chapter we are going to discuss about the experimental work which is consist about
formation of the L-18 orthogonal array based on Taguchi design, orthogonal array is reduces the
total on of experiment, in this experiment total 18 run. And Experimental set up, selection of work
piece, tool design, and taking all the value and calculation of MRR, EWR, and OC and Surface Finish

4.2 Experimental setup:

For this experiment the whole work can be down by Electric Discharge Machine, model
SPARKONIX ( die-sinking type) with servo-head (constant gap) and positive polarity for
electrode was used to conduct the experiments. Commercial grade EDM oil (specific gravity=
0.763, freezing point= 94˚C) was used as dielectric fluid. With internal flushing of circular Cu
tool with a pressure of 0.2 kgf/cm2 .Experiments were conducted with positive polarity of
electrode. The pulsed
discharge current was applied in various steps in positive mode.
The EDM consists of following major part as shown in the fig:

 Dielectric reservoir, pump and circulation system.

 Power generator and control unit.
 Working tank with work holding device.
 X-y table accommodating the working table.
 The tool holder.
 The servo system to feed the tool.

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Fig 4.2.1: EDM machine setup

Dielectric reservoirs pump and circulation system - Dielectric reservoirs
and pump are used to circulate the EDM oil for every run of the experiment and also
used the filter the EDM oil. Dielectric reservoir is shown in fig:

Fig 4.2.2: Dielectric reservoir

Power generator and control unit - The power supply control the amount of energy
consumed. First, it has a time control function which controls the length of time that current
flows during each pulse; this is called “on time.” Then it is control the amount of current al owed
to flow during each pulse. These pulses are of very short duration and are measured in
microseconds. There is a handy rule of thumb to determine the amount of current a
particular size of electrode should use: for an efficient removal rate, each square inch of
electrode calls for 50 A. Low current level for large electrode will extend overall machine time
unnecessarily. Conversely, too heavy a current load can damage the work piece
ofelectrode.The control unit is control the all function of the machining for example of Ton,
Ip, duty cycle, putting the values and maintain the work piece the tool gap. The control unit is
shown in this Fig 4.2.2

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Fig 4.2.3: Control unit of EDM machine

Working tank with work holding device– All the EDM oil kept in the working tank
working tank is used to the supply the fluid during the process of machining..X-y table
accommodating the working table – They are used to the moment of the work piece form X
and Y direction. The tool holder – The tool holder hold the tool with the process of
machining. The tool holder with work piece and tool as shown in Fig 4.2.4. The servo system
to feed the tool - The servo control unit is provided to maintain the pre determined gap. It
senses the gap voltage and compares it with the present value and the different in voltage is
then used to control the movement of servo motor to adjust the gap.

Fig 4.2.4:Tool Holder

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4.3 Selection of the workpiece:

It is capable of machining of hard material component such as heat treated Die Steels,
composites, super alloys, ceramics, carbides, heat resistant steels etc. The higher carbon grades
are typically used for such applications as stamping dies, metal cutting tools, etc. AISI
grades of Die Steel is the most common scale used to identify various grades of Die
Steel. Individual alloys within a grade are given a number; for example: M2, O1, D2, P20etc.
In this experiment we are using M2 Die Steel.M2 High Speed steel (M2) is a Tungsten –
Molybdenum high speed steel with a well-balanced composition suitable for a wide variety of
applications.
M2 Die Steel (work piece) is shown in below fig:4.3.1.

Fig 4.3.1: M2 Die Steel

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4.3.1. Chemical Composition:

Table 02 : Chemical composition of M2 Die Steel

S.No Material Percentage

1. Carbon 0.78-1.05

2. Chromium 3.75-4.5

3. Iron Balance

4. Manganese 0.15-0.4

5. Molybdenum 4.5-5.5

6. Phosphorous 0.03 max

7. Silicon 0.2-0.45

8. Sculpture 0.03 max

9. Tungsten 5.5-6.75

10 Vanadium 1.75-2.2
.

4.3.2 Physical Properties of M2 Die Steel:

Table 03 : Physical Properties of M2 Die Steel

S.No Property Value

1. Density(lb/cumin) 0.295

2. Specific gravity 8.16

3. Melting Poin t(Deg F) 2600

4. Modulus of Elasticity 28

5. Thermal Conductivity 24 W/m/0k

6. Thermal Expansion 65-66HRC

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4.3.3Mechanical Properties of M2Die Steel:

Table 04 : Mechanical Properties of M2 Die steel

Principal Design M2 is a higher carbon version of the M1 Die Steel (Molybdenum High
Feat Speed Die Steel). The M2 alloy has somewhat better wear resistance than M1.
ures
Primarily used for cutting tools.
Applications

Machinability M2 is classified as a "medium" machinability Die Steel in the annealed

condition. It may be shaped by grinding but is relatively poor in regard to
capability of being ground. Its machinability rating is 50% as compared to the
W group water hardening Die Steels which are relatively easily machined.

Forming Formed by machining or forging and then machining.

Consult the alloy supplier for information on the advisability of welding.

Welding
Preheat at 1450 F before heating for hardening. Then heat rapidly from 1450
Heat Treatment F to 2200 F and hold for 3 to 5 minutes followed by quenching in oil, air or salt
bath.

Forging Forge at 2050 F down to 1700 F. Do Not forge below 1700 F.

Hot Working See "Forging" and consult the supplier for information on working at lower
temperatures.

Cold working may be accomplished with the alloy in the annealed condition.
Cold Working

Annealing Anneal at 1625 F and slow furnace cool at 40 F per hour, or less.

Aging Not applicable to this alloy.

Temper at 1050 F for a hardness of Rockwell C 60 to 65.
Tempering

Hardening Hardens by heat treatment and quenching. See "Heat Treatment" and
"Tempering".

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4.4Tool Design:
The tool design for Electric discharge machining for using Cu, brass, Al alloys silver tungsten
alloys etc. In this experiment using the copper tool electrode and the design of cupper tool
is a Circular- shaped with internal flashing. Shapes of the tool same cavity produced in the
work piece. Using the Circular-shaped tool so Circular-shaped cavity produced on the work
piece.

Fig 4.4.1 : Cu and Graphite Tool

4.5 Mechanism of MRR

The mechanism of material removal of EDM process is most widely established
principle is the conversion of electrical energy it into thermal energy. During the process of
machining the sparks are produced between workpiece and tool .Thus each spark produces a tiny
crater, and crater formation in the material along the cutting path by melting and vaporization,
thus eroding the workpiece to the shape of the tool.
It is well-known and elucidated by many EDM researchers by Roethke that Material
Removal Mechanism (MRM) is the process of transformation of material elements between the
work-piece and electrode. The transformation are transported in solid, liquid or gaseous state,
and then alloyed with the contacting surface by undergoing a solid, liquid or gaseous phase reaction.

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4.5.1 Evaluation of MRR-

The material MRR is expressed as the ratio of the difference of weight of the
work piece before and after machining to the machining time and density of the
material

MRR = Wjb–Wja / (t * q )

Whereas
Wjb = Weight of workpiece before machining.

Wja = Weight of workpiece after machining

Fig 4.5.1:-Measuring work piece weight by Weighing Machine

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4.6 Mechanism of Electrode Wear :

Electrode Wear is an important factor because if affects dimensional accuracy and the
shape produced. Electrode Wear is related to the melting point of the materials.
Electrode Wear is affected by the precipitation of carbon from the hydrocarbon dielectric
on the electrode surface during sparking. By Mohri .Also the rapid wear on the electrode
edge was because of the failure of carbon to precipitate at difficult to reach regions of the
electrode.

4.6.1 Evaluation of Electrode Wear rate

EWR is expressed as the ratio of the difference of weight of the tool before and after machining to the
machining time. That can be explain this equations

EWR= (Wtb –Wta)/t Whereas Wtb = Weight of tool before

machining
Wta = Weight of the tool after machining.

Fig: - 4.6.1: Weighing Machine Weighing TOOL

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4.7 EXPERIMENTATION:
Experiments were conducted on a die sinking EDM SPARKONIX S 35 machine. In this
study, M2 Die Steel is selected as the work material.. A cylindrical electrode with circular
section having 12 mm diameter cooper and graphite were used as the electrodes (tool).
Figure 2 shows a typical copper and graphite electrodes used in the experimentation.
Figure 3 shows the work pieces of M2 Die steel after machining with the copper and
graphite tools.EDM-30 oil is taken as dielectric fluid. A total of 16 readings are taken for
each tool i.e., copper & graphite. The effect of discharge current and pulse duration has
been taken into consideration. Discharge current is varied from min to maximum of EDM
machine range i.e., 5 amp to 34 amp. Voltage is kept constant for every four readings, from
40 V-60 V, for four different pulse on & pulse off times 7,8,9,10 sec. Depth of cut is taken
as 0.5 mm. Surface Roughness is measured with METRIX + SURFACE ROUGHNESS
TESTER. Finally MRR, EWR and Surface Roughness is calculated and plotted the graphs
with respect to power.

Fig 4.7.1: Work pieces after machining

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CHAPTER -5

RESULTS & DISCUSSIONS

5.1 INTRODUCTION:
In This chapter are related about influences of MRR, EWR, and Surface Roughness and
finding the result which factors discharge current, pulse duration, diameter of Cu tool is
analyzed.

5.2 Results Regarding Parameters:

Ra vs
14 GraphiteR
a
Power
1
2
1
0
8
6
4
2
200 280 360 400 540 630 720 810 1000 1100 1200 1300 1680 1800 1920 2040
0

Fig 5.1: Surface Roughness of Graphite Tool vs Power

The variation of Surface Roughness of Graphite Tool with respect to power is shown in the
above graph. Surface Roughness increases when applied discharge current increases, hence power.
Maximum Ra occurs at 1100 watts.

MRR vs Power
140
120
GraphiteMRR
100
80
60
40
20
0
200 280 360 400 540 630 720 810 10001100120013001680180019202040
Power
Fig 5.2 : MRR of Graphite Tool vs Power

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The variation of Material Removal Rate of Graphite Tool with respect to power is
shown in the above graph. MRR increases when applied discharge current and voltage
increases, hence power. Maximum MRR occurs at 2400 watts.

EWR vs POWER
0.9
0.8
0.7
0.6
0.5
0.4
0.3
Graphite EWR
0.2
0.1
0
200 280 360 400 540 630 720 810 1000110012001300168018001 9202040
Power

Fig 5.3: EWR of Graphite Tool vs. Power

The variation of Electrode Ware Rate of Graphite Tool with respect to power is shown in the
above graph. EWR increases when applied discharge current and voltage increases, hence power.
Maximum EWR occurs at 1680 watts.

MRR vs POWER
140
120
100
80
60
40 Copper MRR
20
0
200 280 360 400 540 630 720 810 10001100120013001680180019202040

Power

Fig 5.4 : MRR of Copper Tool vs Power

The variation of Electrode Ware Rate of Copper Tool with respect to power is shown in
the above graph. EWR increases when applied discharge current and voltage increases, hence
power. Maximum EWR occurs at 1920 watts.

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Ra vs POWER
14
12
Copper Ra
10
8
6
4
2
0
200 280 360 400 540 630 720 810 10001100120013001680180019202040

Power

Fig 5.5 : Surface Roughness of Copper Tool vs Power

The variation of Surface Roughness of Copper Tool with respect to power is shown in
the above graph. Surface Roughness increases when applied discharge current increases, hence
power. Maximum Ra occurs at 1920 watts.

EWR vs Power
0.6 POGGPOPPPP
0.5 PPPPPPpPPPP
0.4 PPPPPPPPPPP
0.3 PPPPPPPPppp
ppppOWERP
0.2 EWR
0.
POWER
1
0

Powe
r
Fig 5.6 : EWR of Copper Tool vs Power

The variation of Electrode Ware Rate of Copper Tool with respect to power is shown in the
above graph. EWR increases when applied discharge current and voltage increases, hence power.
Maximum EWR occurs at 2040 watts.

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Fig 5.7: Material Removal Rate of Copper Tool vs Pulse on Time

The variation of Material removal rate for copper tool with respect to four different pulse on times is
shown in the above graph. The graph shows that MRR increases when pulse on time increases.

Fig 5.8: Surface Roughness of Copper Tool vs Pulse on Time

The variation of Surface Roughness for copper tool with respect to four different pulse on
times is shown in the above graph. The graph shows that Ra decreases when pulse on time
increases.

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Fig 5.9: Electrode Wear Rate of Copper Tool vs Pulse on Time

The variation of Electrode Wear rate for copper tool with respect to four different pulse on times
is shown in the above graph. The graph shows that MRR increases linearly when pulse on time
increases.

Fig 5.10: Material Removal Rate of Graphite Tool vs Pulse on Time

The variation of Material removal rate for Graphite tool with respect to four different pulse
on times is shown in the above graph. The graph shows that MRR increases when pulse on time
increases.

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Fig 5.11: Surface Roughness of Graphite Tool vs Pulse on Time

The variation of Surface Roughness for graphite tool with respect to four different pulse on
times is shown in the above graph. The graph shows that Ra decreases when pulse on time increases.

Fig 5.12: Electrode wear Rate of Graphite Tool vs Pulse on Time

The variation of Electrode Wear rate for graphite tool with respect to four different pulse on
times is shown in the above graph. The graph shows that MRR increases linearly when pulse on time
increases.

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140
MRR Vs Power
120
100 Copper MRR
GraphiteMRR
80
60
40
20
0
200 280 360 400 540 630 720 810 1000 1100 1200 1300 1680 1800 1920 2040
POWER

Fig 5.13: Comparison of MRR for Copper & Graphite tool w.r.t. Power
The variation of MRR with respect to Power for machining M2 Die steel is shown in
figure. The graph shows that MRR increases with respect to power for both Copper and
Graphite tools.When Copper tool is used for machining, MRR is varied from minimum of 20
mm3/min to maximum of 128 mm3/min.Maximum MRR is at 1920 watts and then MRR is reduced
due to high variation in Pulse on & off timings. For Graphite tool MRR is raised in a linear manner
with a maximum MRR of 134 mm3/min at 2040 watts.

EWR VS POWER
1
0.8 Graphite EWR
0.6 Copper EWR
0.4

0.2
0
200 280 360 400 540 630 720 810 1000 1100 1200 1300 1680 1800 1920 2040

POWER

Fig 5.14: Comparison of EWR for Copper & Graphite tool w.r.t. Power

The variation of EWR with respect to Power for machining M2 Die steel is shown in figure.
electrode wear rate for Graphite electrode raises from power 200 wts to 630 wts linearly and
then EWR is raised exponentially upto 1300 wts.For Copper electrode MRR Is varied linearly
upto the power 1300 wts and then exponentially to 2040 wts with a maximum of 0.56 mm3/min.
The graph shows that EWR increases with respect to power for both Copper and Graphite tools.

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14
Ra Vs Power
12

10
8
Ra

6
GraphiteRa
4
Copper Ra
2
0

200 280 360 400 540 630 720 810 1000 1100 1200 1300 1680 1800 1920 2040
Power

Fig 5.15: Comparison of Ra for Copper & Graphite tool w.r.t. Power
The variation of Ra with respect to Power for machining M2 Die steel is shown in figure.
For Cu Tool, Surface roughness is varied in a zig zag manner due to variations in Pulse on and
pulse off time. The surface is very rough at 1000 wts for Graphite electrode and 1920 wts for
Copper electrode. Whenever Current is raised roughness is increasing with a higher rate for
Graphite, compared with Copper.
The above graph shows that Ra increases with respect to power for both Copper and Graphite tools.

140
120
GraphiteMRR 100
GraphiteRa 80
Graphite EWR 60
Copper MRR 40
Copper Ra 20
Copper EWR 0

Fig 5.16: Comparison of all parameters for Copper & Graphite tool w.r.t. Power
The variation of all parameters with respect to Power for machining M2 Die steel for both
Copper and Graphite tools is shown in the above figure. The above bar graph shows that all
the three parameters are directly proportional to power. High amount of material is removed
when graphite tool is used but at the same time more amount of tool is eroded.

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Table-5: Experimental results for machining with Graphite tool

Voltage Power MRR EWR

S.No I-(amp) T-on T-off V Watts mm3/min Ra, µm mm3/min

1 5 7 7 40 200 15.832 2.066 0.396

2 7 8 8 40 280 7.961 3.98 0.414

3 9 9 9 40 360 24.071 3.15 0.211

4 10 10 10 40 400 14.2336 2.619 1.054

5 12 7 8 45 540 48.733 9.039 1.065

6 14 8 7 45 630 72.543 9.36 1.088

7 16 9 10 45 720 71.0458 11.12 1.456

8 18 10 9 45 810 85.139 11.78 1.365

9 20 7 7 50 1000 81.139 12.77 1.894

10 22 8 9 50 1100 79.3654 10.515 1.843

11 24 9 7 50 1200 85.139 11.24 1.753

12 26 10 8 50 1300 76.307 10.44 0.536

13 28 7 9 60 1680 85.414 13.24 0.621

14 30 8 9 60 1800 119.339 12.995 0.149

15 32 9 8 60 1920 112.333 10.4 0.241

16 34 10 7 60 2040 133.225 11.11 0.156

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Table-6: Experimental results for machining with Copper tool

Voltage Power MRR EWR

S.No I-(amp) T-on T-off V Watts mm3/min Ra, µm mm3/min

1 5 7 7 40 200 21.2107 5.869 0.0357

2 7 8 8 40 280 31.8095 3.27 0.0123

3 9 9 9 40 360 23.3395 5.98 0.0221

4 10 10 10 40 400 27.5687 4.329 0.0035

5 12 7 8 45 540 21.6724 7.639 0.0957

6 14 8 7 45 630 35.3648 10.18 0.1282

7 16 9 10 45 720 47.9795 9.119 0.0706

8 18 10 9 45 810 47.9795 9.86 0.0672

9 20 7 7 50 1000 68.1254 9.5 0.1563

10 22 8 9 50 1100 72.9359 9.54 0.1104

11 24 9 7 50 1200 103.245 10.975 0.1116

12 26 10 8 50 1300 115.116 9.173 0.0181

13 28 7 9 60 1680 96.3215 11.28 0.5432

14 30 8 9 60 1800 108.321 10.82 0.5642

15 32 9 8 60 1920 128.721 12.717 0.5073

16 34 10 7 60 2040 115.321 10.25 0.0366

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5.3 Results regarding Crater Shape:

The final shape of the crater as a result of a single pulse is quite well known to
researchers. It is a depression in the middle with edges that are raised above the surface
(photographs are included in this document). This shape is formed as a result of two
effects. During the plasma-on time the plasma pressure holds the liquid metal in place under
pressure. This may force some of the fluid to be pushed towards the side and try and escape
the pressure. It is assumed these liquids resolidify to form the protruding edges around the
hole. When the plasma pressure is released violently ejected liquid metal splatters and this
leaves splashy re-solidified material all over the crater. In the simulation the depression
within the crater is automatically simulated when the molten material is removed. To simulate
the protruding edges a pressure boundary condition is applied on the molten pool and the
pressure is kept on until the pulse-on time. This forces some of the molten material to severely
shear and form the edge around the pool.
Microstructures of Tools by using Scanning Electron Microscope (SEM) are shown below.

Fig 5.3.1: SEM of Copper Tool before machining

Fig 5.3.2: SEM Copper Tool after machining

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Fig 5.3.3: SEM Of Graphite Tool before machining

Fig 5.3.4: SEM of Graphite tool after machining

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CHAPTER -6
CONCLUSION
Experiments on EDM of M2 Die steel were carried out. Pulse on, Pulse off, peak
current, voltage are the primary parameters and dielectric fluid, flushing pressure ,electrode
rotation of the non electric parameters are considered in EDM.Most of the research work has
been carried out for improving the performance on EDM are measured in terms of Material
Removal Rate, Electrode Wear Rate and Surface Roughness. The major conclusion from
this investigation can be summarized as follows
A. Metal Removal Rate (MRR) increases with increase of power.

B. Surface Roughness (Ra) increases with increase of power.

C. Electrode Wear Rate (EWR)) increases with increase of power.

D. Metal Removal Rate (MRR) increases with increase of pulse on Time

E. Surface Roughness (Ra) decreases with increase of pulse on time

F. Electrode Wear Rate (EWR) ) increases with increase of power

G. Copper Tool is efficient for M2 Die steel when we considered the parameters MRR, EWR,

Surface roughness.

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FUTURE SCOPE:
EDM can be used for machining hard materials such as Nickel based alloys, Aluminum
alloys, Titanium alloys and chromium based alloys which are used in the applications of
Aerospace, Ship building and turbine blade manufacturing applications. It can be used for
machining of newly composite materials with various applications. It can be used in such
cases where work piece is harder than tool material and dimensional accuracy, surface
integrity plays a vital role.

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CHAPTER -7
REFERENCES

[1]S. Rajesha, A. K. Sharma, and P. Kumar, “On electro discharge machining of inconel 718
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