International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN INTERNATIONAL JOURNAL OF ADVANCED RESEARCH IN 0976 6480(Print),

, ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME ENGINEERING AND TECHNOLOGY (IJARET) ISSN 0976 - 6480 (Print) ISSN 0976 - 6499 (Online) Volume 4, Issue 3, April 2013, pp. 158-162 IAEME: www.iaeme.com/ijaret.asp Journal Impact Factor (2013): 5.8376 (Calculated by GISI) www.jifactor.com

IJARET
IAEME

A STUDY ON INFLUENCE OF POLARITY ON THE MACHINING CHARACTERISTICS OF SINKER EDM

A. Parshuramulu1, K. Buschaiah2* and P. Laxminarayana3
1

Asst. Professor, University College of Technology, OsmaniaUniversity, Hyderabad, A.P. 500007

2*

Scientist, Department of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad, A.P. 500007. Professor, Department of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad, A.P. 500007.
3

ABSTRACT Electrical discharge machining (EDM) has been recognized as an efficient production method for precision machining of electrically conducting hardened materials. Electrical Discharge Machining is a machining method primarily used for hard metals or those that would be impossible to machine with traditional techniques. One critical limitation, however, is that EDM only works with materials that are electrically conductive. Sometimes referred to as spark machining or spark eroding, EDM is a nontraditional method of removing material by a series of rapidly recurring electric arcing discharges between an electrode (the cutting tool) and the work piece, in the presence of an energetic electric field. The most important study of this paper is the effect of the polarity on the machining tool / work piece using electrical discharge machining to the material removal rate, electrode wear and surface roughness, to determine the optimum condition, and to determine the most significant factor. In this paper an elaborative methodology is suggested to choose option between electrode and work piece as terminal positive or terminal negative for different categories of tools and work pieces. The wrong polarity can have significant implications on wear, and stability. A set of experiments are conducted and the results are represented numerically and graphically. The most important output parameters are material removal rate, electrode wear and surface roughness. From the obtained data one can easily determine the optimum parameters and most significant factors related to material removal rate (MRR), electrode wear and surface finish very easily. Index Terms: Material removal rate (MRR), Straight and reverse polarity, Surface roughness. 158

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME I. INTRODUCTION Electrical Discharge Machining (or EDM) is a machining method primarily used for hard metals or those that would be impossible to machine with traditional techniques. One critical limitation, however, is that EDM only works with materials that are electrically conductive. EDM can cut small or odd-shaped angles, intricate contours or cavities in pre-hardened steel without the need for heat treatment to soften and re-harden them as well as exotic metals such as titanium, hastelloy, and inconel. The control parameters optimization for individual machining characteristic is concerned with separately maximize the material removal rate, separately minimize the tool wear ratio and separately obtained a good surface finish. There are many input parameters which can be varied in the EDM process which have different effects on the EDM machining characteristics. Sometimes referred to as spark machining or spark eroding, EDM is a nontraditional method of removing material by a series of rapidly recurring electric arcing discharges between an electrode (the cutting tool) and the work piece, in the presence of an energetic electric field. The EDM cutting tool is guided along the desired. path very close to the work but it does not touch the piece [1]. Consecutive sparks produce a series of micro-craters on the work piece and remove material along the cutting path by melting and vaporization. The particles are washed away by the continuously flushing dielectric fluid. It is also important to note that a similar micro-crater is formed on the surface of the electrode, the debris from which must also be flushed away [2]. II. THEORY Experimental research generally targets regression analysis of process parameters and modeling to optimize the process characteristics. This involves maximization of machining rate and minimization of tool wear and surface roughness. This also helps in the development of adaptive control systems. The advances in computer applications in manufacturing processes and their control has led to the development of artificial intelligence approaches in the form of expert systems, neural networks and fuzzy logic towards optimization and other control systems like prevention of wire rupture. However most of the experimental research has a simplistic approach and tries the variation of dielectric (hydrocarbons and water based) and electrode materials (Copper, tungsten, graphite etc.), method of gap flushing (tool rotation, vibration or oscillation, magnetic and ultrasonic fields application) and studies of surface integrity (hardness, residual stress, defects like micro cracks alloying with electrode material). The other type of popular research area is hybridization of EDM with another assisting process for combining the beneficial features of both processes. In the case of EDM the assistance of Electro Chemical Machining, Ultrasonic Machining and magnetic field have been reported. In spite of being so extensively researched there are considerable grey areas in the literature on the EDM process and the associated theories and mechanism [3]. III. STRAIGHT AND REVERSE POLARITY For a better understanding of spark erosion mechanism, and the final surface characteristics which includes morphological, metallurgical and textural features it is always necessary to study the effect of polarity which is defined as reverse polarity (electrode positive) and straight polarity (electrode negative) [4]. IV. DESCRIPTION OF EXPERIMENTAL SETUP An experimental study was carried out on CREATOR CR-6C (SY CNC PC-60) Electric discharge machine with hydrocarbon oil (ED-30 oil) as the dielectric fluid. The selected work piece material is stainless steel in the form of rectangular shapes of 20mm20mm5mm. A cylindrical copper 159

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME tool with a diameter of 12mm was used as an electrode which was finish ground before experimental study and was mounted axially in line with work pieces. 12 specimens of stainless steel have been taken for experiment. Those have been made as rectangular shape of 20mm20mm5mm pieces. By varying the current (6, 8,10,12,14 & 16 Amps) i.e., 6 specimens each for both Straight and Reverse polarity machining is carried out keeping time of observation as 20 minutes. The specimens are weighed before and after the machining, the difference of both is considered to arrive at the Material Removal Rate (MRR). Surface roughness for 12 specimens of stainless steel has been measured by using stylus type instrument. The sampling length taken was 5mm. Surface morphology was also studied in depth using SEM photographs on all the 12 specimens (six specimens in straight polarity and six specimens in reverse polarity) V. RESULTS AND DISCUSSIONS A. Material Removal Rate: The effect of polarity was interesting whereby negative polarity produced shallow and small craters whereas positive polarity led to larger craters. B. Morphology and integrity of EDM surfaces: The physical and metallurgical studies of EDM surfaces show some interesting aspects. The spark eroded surfaces are matty in appearances owing to the overlapping spark craters. Ideally these craters are expected to be spherical as a result of melting from the spark energies with the assumptions of a point source of heat with dissipation radially there from. In practice the evacuation of molten metal from spark craters is not complete and owing to variables energies in the spark trains the crater sizes also differ, leading to the formation of a randomly varying surface morphology (Fig.1). Erosion in molten form is also evident from spherical debris trapped in the resolidified residual layer. This apart the eroded surfaces exhibit typical EDM characteristics of micro cracks and gas pockets. The absorption of carbon from the pyrolysis of hydrocarbon dielectric leads to the formation of hard carbides, which form a hard surface layer, which is not etchable by the conventional etchant and appears and so names as White Layer [5], [10], [11].

(a)

(b)

Fig. 1. SEM photographs after EDM of steel surfaces (a) Straight polarity and (b) Reverse polarity 160

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME Electrode positive setup is superior in the form of high erosion of work material. This in machining terminology is equivalent to high machining rates. This is due to higher liberation of spark energy at cathode which absorbs ions higher mass through the plasma channel dimensions compared to electrons absorbed at anode which are of negligible mass and result in large and expanded channel dimensions due to mutual repulsion leading to low energy concentration. Next in importance is the effect of pulse current on erosion rate. But this is a well established fact. The pulse energy is being a product of pulse voltage, current and on time, naturally any increase in these variables results in higher erosion rates both at work and electrodes surfaces. Of all these the effect of pulse current is higher [6]. (A) (B)

Fig. 2. EDAX photographs after EDM of steel surfaces (a) Straight polarity and (b) Reverse polarity.

There is evidence of inter-electrode mass transfer whereby the anodic electrode material gets diffused on to the cathodic work surface. EDXA analysis shows such a mass transfer where electrode is anode (Fig.2). One can anticipate higher roughness to be associated with higher erosion rates and is certainly evident in most of the results. The only exception being the pulse times. The factor, which promotes spark erosion, also promotes surface roughness owing to larger size of spark craters. Consequently the effects of polarity, pulse current and pulse voltage are similar on erosion rates and roughness. But in the case of pulse on time the roughness is reduced though erosion rate increase significantly. This phenomenon is attributed once again to expansion of spark channel, which not only reduces the energy concentration but also results in higher diameter of spark craters. Though the effect of both pulse current and on time are similar in increasing the size of spark craters , leading to higher erosion rates, their effect on the geometry of the spark craters is different. Increase in current for the same pulse on time results in deeper craters owing to higher energy concentration. On the other hand the increase in pulse on time promotes plasma channel expansion thus leading to larger diameter of spark craters. VI. CONCLUSIONS Summarizing the main features of the present experimental work, the following conclusions were drawn: 1. It is evident from the results obtained that, the polarity and current setting have dominant effect on erosion rates of steel. 161

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME 2. Pulse current has direct effect on both MRR and surface roughness, which are increasing with increase in the former for both the polarities. 3. Electrode positive and higher currents produce higher erosion rates compared to electrode negative at higher currents for steel. 4. MRR obtained is in the range of 5.94 24.46 mm3/min in case of reverse polarity, whereas in case of straight polarity the range obtained is 0.035 0.120 mm3/min for same peak pulse current and time of machining. 5. Surface roughness obtained is in the range of 1.72 5.92 m in case of straight polarity, whereas in case of reverse polarity the range obtained is 7.36 12.64m for same peak pulse current and time of machining. 6. It is inferred that higher current promote deeper craters and higher roughness. Finally the following concluding remarks are put forth about the practical significance of these studies. For improving erosion rates reverse polarity and higher pulse currents are advisable to electrode positive. For improving the surface finish slower erosion is advisable which is possible with straight polarity only. REFERENCES
1. S.H.Tomadi et al, Analysis of the influence of EDM Parameters on Surface Quality, Material removal rate and electrode wear of tungsten carbide, IMECS 2009 march 18-20, 2009, Hongkong. 2. K.H. Ho, S.T. Newman, State of the art electrical discharge machining (EDM), Int. journal of machine tools & manufacture 43 (2003) 1287-1300. 3. Norliana Mohd Abbas et al, A review on current research trends in electrical discharge machining(EDM),Int. journal of machine tools & manufacture 47(2007) 1214 -1228. 4. C.H. Che Haron et al, Investigation on the influence of machining parameters when machining tool steel using EDM, Journal of Materials Processing Technology 116(2001) 84-87. 5. Seong Min Son et al, Influences of pulsed power condition on the machining properties in micro EDM, Journal of Materials Processing Technology 190(2007) 73-76. 6. Ahmet Hascalik, Ulas Caydas, Electrical discharge machining of titanium alloy (Ti-6Al-4V), Applied surface science 253(2007) 9007-9016. 7. J.C. Rebelo et al, Influence of EDM pulse energy on the surface integrity of martensitic steels, Journal of Materials Processing Technology 84(1998) 90-96. 8. Shankar Singh et al, Some investigations into the electric discharge machining of hardened tool steel using different electrode materials, Journal of Materials Processing Technology 149(2004) 272-277. 9. Gokul Vasudevamurthy, Travis W. Knight, Effect of system parameters on size distribution of 304 stainless steel particles produced by electrical discharge mechanism, Materials letters 61(2007) 48724874. 10. Bhattacharyya et al, Modelling and analysis of EDMED job surface integrity, Journal of Materials Processing Technology 189(2007) 169-177. 11. S.H.Lee, X.P.Li, Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide, Journal of Materials Processing Technology 115(2001) 344-358. 12. A. Hemantha Kumar , Krishnaiah.G, V.Diwakar Reddy, Ann Based Prediction Of Surface Roughness In Turning International Journal Of Mechanical Engineering & Technology (IJMET) Volume 3, Issue 2 , 2012, pp. 162 - 170, ISSN PRINT : 0976 6340, ISSN ONLINE : 0976 - 6359. 13. P.B.Wagh, R.R.Deshmukh And S.D.Deshmukh, Process Parameters Optimization For Surface Roughness In Edm For Aisi D2 Steel By Response Surface Methodology International Journal Of Mechanical Engineering & Technology (IJMET) Volume 4, Issue 1, 2013, pp. 203 - 208, ISSN PRINT : 0976 6340, ISSN ONLINE : 0976 - 6359

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