Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics

Abstract This paper concerned with study the effect of a graphite micro powder mixed in the kerosene dielectric fluid during powder mixing electric discharge machining (PMEDM) of high carbon high chromium AISI D2 steel. The type of electrode (copper and graphite), the pulse current and the pulse...

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Autores principales:	Ahmed N. Al-Khazraji, Samir A. Amin, Saad M. Ali
Formato:	article
Lenguaje:	EN
Publicado:	Al-Khwarizmi College of Engineering – University of Baghdad 2015
Materias:	Keywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040
Acceso en línea:	https://doaj.org/article/f8976b022df446a1ad0bf5e5aee9b304
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spelling	oai:doaj.org-article:f8976b022df446a1ad0bf5e5aee9b3042021-12-02T06:16:27ZStudying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics1818-11712312-0789https://doaj.org/article/f8976b022df446a1ad0bf5e5aee9b3042015-06-01T00:00:00Zhttp://alkej.uobaghdad.edu.iq/index.php/alkej/article/view/241https://doaj.org/toc/1818-1171https://doaj.org/toc/2312-0789 Abstract This paper concerned with study the effect of a graphite micro powder mixed in the kerosene dielectric fluid during powder mixing electric discharge machining (PMEDM) of high carbon high chromium AISI D2 steel. The type of electrode (copper and graphite), the pulse current and the pulse-on time and mixing powder in kerosene dielectric fluid are taken as the process main input parameters. The material removal rate MRR, the tool wear ratio TWR and the work piece surface roughness (SR) are taken as output parameters to measure the process performance. The experiments are planned using response surface methodology (RSM) design procedure. Empirical models are developed for MRR, TWR and SR, using the analysis of variance (ANOVA).The best results for the productivity of the process (MRR) obtained when using the graphite electrodes, the pulse current (22 A), the pulse on duration (120 µs) and using the graphite powder mixing in kerosene dielectric reaches (82.84mm³/min). The result gives an improvement in material removal rate of (274%) with respect to the corresponding value obtained when copper electrodes with kerosene dielectric alone. The best results for the tool wear ratio (TWR) of the process obtained when using the copper electrodes, the pulse current (8 A), the pulse on duration (120 µs) and using the kerosene dielectric alone reaches (0.31 %). The use of graphite electrodes, the kerosene dielectric with 5g/l graphite powder mixing, the pulse current (8 A), the pulse on duration (40 µs) give the best surface roughness of a value (2.77 µm).This result yields an improvement in SR by (141%) with respect to the corresponding value obtained when using copper electrodes and the kerosene dielectric alone with the same other parameters and machining conditions. Keywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing. Ahmed N. Al-KhazrajiSamir A. AminSaad M. AliAl-Khwarizmi College of Engineering – University of BaghdadarticleKeywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing.Chemical engineeringTP155-156Engineering (General). Civil engineering (General)TA1-2040ENAl-Khawarizmi Engineering Journal, Vol 11, Iss 3 (2015)
institution	DOAJ
collection	DOAJ
language	EN
topic	Keywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040
spellingShingle	Keywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040 Ahmed N. Al-Khazraji Samir A. Amin Saad M. Ali Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
description	Abstract This paper concerned with study the effect of a graphite micro powder mixed in the kerosene dielectric fluid during powder mixing electric discharge machining (PMEDM) of high carbon high chromium AISI D2 steel. The type of electrode (copper and graphite), the pulse current and the pulse-on time and mixing powder in kerosene dielectric fluid are taken as the process main input parameters. The material removal rate MRR, the tool wear ratio TWR and the work piece surface roughness (SR) are taken as output parameters to measure the process performance. The experiments are planned using response surface methodology (RSM) design procedure. Empirical models are developed for MRR, TWR and SR, using the analysis of variance (ANOVA).The best results for the productivity of the process (MRR) obtained when using the graphite electrodes, the pulse current (22 A), the pulse on duration (120 µs) and using the graphite powder mixing in kerosene dielectric reaches (82.84mm³/min). The result gives an improvement in material removal rate of (274%) with respect to the corresponding value obtained when copper electrodes with kerosene dielectric alone. The best results for the tool wear ratio (TWR) of the process obtained when using the copper electrodes, the pulse current (8 A), the pulse on duration (120 µs) and using the kerosene dielectric alone reaches (0.31 %). The use of graphite electrodes, the kerosene dielectric with 5g/l graphite powder mixing, the pulse current (8 A), the pulse on duration (40 µs) give the best surface roughness of a value (2.77 µm).This result yields an improvement in SR by (141%) with respect to the corresponding value obtained when using copper electrodes and the kerosene dielectric alone with the same other parameters and machining conditions. Keywords: EDM, RSM, MRR, TWR, SR, AISI D2die steel, graphite powder mixing.
format	article
author	Ahmed N. Al-Khazraji Samir A. Amin Saad M. Ali
author_facet	Ahmed N. Al-Khazraji Samir A. Amin Saad M. Ali
author_sort	Ahmed N. Al-Khazraji
title	Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
title_short	Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
title_full	Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
title_fullStr	Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
title_full_unstemmed	Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics
title_sort	studying and modeling the effect of graphite powder mixing electrical discharge machining on the main process characteristics
publisher	Al-Khwarizmi College of Engineering – University of Baghdad
publishDate	2015
url	https://doaj.org/article/f8976b022df446a1ad0bf5e5aee9b304
work_keys_str_mv	AT ahmednalkhazraji studyingandmodelingtheeffectofgraphitepowdermixingelectricaldischargemachiningonthemainprocesscharacteristics AT samiraamin studyingandmodelingtheeffectofgraphitepowdermixingelectricaldischargemachiningonthemainprocesscharacteristics AT saadmali studyingandmodelingtheeffectofgraphitepowdermixingelectricaldischargemachiningonthemainprocesscharacteristics
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Studying and Modeling the Effect of Graphite Powder Mixing Electrical Discharge Machining on the Main Process Characteristics

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