Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR

This paper investigates micro electrical discharge (ED) milling for AISI 420 and Stavax ESR stainless steel using tungsten carbide electrode. For each of the materials, experiments have been conducted using the full factorial combination of gap voltage, capacitance and feed rate. Two responses mate...

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Main Authors:	Mohammad, Yeakub Ali, Khan, Ahsan Ali, Hamzah, Munirah, Khalid, Nor Azura
Format:	Article
Language:	English
Published:	Universiti Malaya 2009
Subjects:	TS200 Metal manufactures. Metalworking
Online Access:	http://irep.iium.edu.my/2699/ http://irep.iium.edu.my/2699/ http://irep.iium.edu.my/2699/1/Yeakub_2.pdf

id	iium-2699
recordtype	eprints
spelling	iium-26992011-11-17T06:58:35Z http://irep.iium.edu.my/2699/ Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR Mohammad, Yeakub Ali Khan, Ahsan Ali Hamzah, Munirah Khalid, Nor Azura TS200 Metal manufactures. Metalworking This paper investigates micro electrical discharge (ED) milling for AISI 420 and Stavax ESR stainless steel using tungsten carbide electrode. For each of the materials, experiments have been conducted using the full factorial combination of gap voltage, capacitance and feed rate. Two responses material removal rate (MRR)and electrode wear ratio (EWR) are analyzed. Both MRR and EWR are found to be higher for AISI 420 compared to that of Stavax for the same machining parameters and environment. Empirical models are developed for the estimation of MRR and EWR. The empirical relationship shows that the feed rate and capacitance are the most important factors for MRR. However, gap voltage and capacitance are the main influential factors for EWR. Although the trend of relationship of MRR and EWR is found to be similar for both materials, the level of influence is found to be significantly different. For multiple optimization of MRR and EWR, the machining parameters are determined analytically and verified experimentally. The optimized values of gap voltage and feed rate are 100 V and 6 μm.s-1 for both materials. However, the optimized capacitance is 8.55 nF and 1 nF for AISI 420 and Stavax ESR respectively. The verification experiment shows that the measured values of MRR and EWR are within 5-10% of the predicted values. For the Stavax ESR the MRR and EWR are found lower than that for AISI 420. The possible reasons of these lower MRR and EWR are discussed. Universiti Malaya 2009 Article PeerReviewed application/pdf en http://irep.iium.edu.my/2699/1/Yeakub_2.pdf Mohammad, Yeakub Ali and Khan, Ahsan Ali and Hamzah, Munirah and Khalid, Nor Azura (2009) Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR. International Journal of Mechanical and Materials Engineering (IJMME), 4 (3). pp. 300-308. ISSN 1823-0334 http://ejum.fsktm.um.edu.my/ArticleInformation.aspx?ArticleID=818
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TS200 Metal manufactures. Metalworking
spellingShingle	TS200 Metal manufactures. Metalworking Mohammad, Yeakub Ali Khan, Ahsan Ali Hamzah, Munirah Khalid, Nor Azura Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
description	This paper investigates micro electrical discharge (ED) milling for AISI 420 and Stavax ESR stainless steel using tungsten carbide electrode. For each of the materials, experiments have been conducted using the full factorial combination of gap voltage, capacitance and feed rate. Two responses material removal rate (MRR)and electrode wear ratio (EWR) are analyzed. Both MRR and EWR are found to be higher for AISI 420 compared to that of Stavax for the same machining parameters and environment. Empirical models are developed for the estimation of MRR and EWR. The empirical relationship shows that the feed rate and capacitance are the most important factors for MRR. However, gap voltage and capacitance are the main influential factors for EWR. Although the trend of relationship of MRR and EWR is found to be similar for both materials, the level of influence is found to be significantly different. For multiple optimization of MRR and EWR, the machining parameters are determined analytically and verified experimentally. The optimized values of gap voltage and feed rate are 100 V and 6 μm.s-1 for both materials. However, the optimized capacitance is 8.55 nF and 1 nF for AISI 420 and Stavax ESR respectively. The verification experiment shows that the measured values of MRR and EWR are within 5-10% of the predicted values. For the Stavax ESR the MRR and EWR are found lower than that for AISI 420. The possible reasons of these lower MRR and EWR are discussed.
format	Article
author	Mohammad, Yeakub Ali Khan, Ahsan Ali Hamzah, Munirah Khalid, Nor Azura
author_facet	Mohammad, Yeakub Ali Khan, Ahsan Ali Hamzah, Munirah Khalid, Nor Azura
author_sort	Mohammad, Yeakub Ali
title	Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
title_short	Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
title_full	Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
title_fullStr	Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
title_full_unstemmed	Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR
title_sort	study of material removal rate and electrode wear ratio for micro electrical discharge milling of aisi 420 and stavax esr
publisher	Universiti Malaya
publishDate	2009
url	http://irep.iium.edu.my/2699/ http://irep.iium.edu.my/2699/ http://irep.iium.edu.my/2699/1/Yeakub_2.pdf
first_indexed	2023-09-18T20:10:19Z
last_indexed	2023-09-18T20:10:19Z
_version_	1777407433922052096

Study of material removal rate and electrode wear ratio for micro electrical discharge milling of AISI 420 and Stavax ESR

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