Beruflich Dokumente
Kultur Dokumente
A Thesis
Submitted to the Department of Production Engineering and
Metallurgy / University of Technology in a Partial Fulfillment of
the Requirements for the Degree of Master of Science in
Production Engineering
By
Haneen Lateef Abdulwahhab
Supervised by
Asst. Prof. Dr. Shukry Hammed Aghdeab
ونِخَبِيرِ(﴾ِ)۱۱
تَ ْعمَل َِ
الع ِظيم
قِاللهِ َ
صدَ َِ
س ورةالم ج ادل ة
Dedication
To my country
friends
A
Table of Contents
Subject Page
No.
Abstract A
List of Contents B
List of Figures H
List of Tables N
List of Abbreviations S
List of Symbols T
List of Contents
Subject Page
No.
B
1.4.1.c Current 9
1.4.1.d Voltage 10
2.1 Introduction 20
2.3 Objective 35
3.1 Introduction 36
C
3.2 EDM Machine 36
4.1 Introduction 54
D
4.4.2 Effect of pulse-on-time and current on EWR 65
E
4.7.2 Effect of pulse-on-time and current on EWR 79
4.8 The effect of different dielectric on MRR, EWR, SR, WLT and 83
HV
4.8.4 Analysis WLT for transformer oil, gas, kerosene and vegetable 87
oil
F
4.9.2.b. Determining Degree of Regression Model for EWR 106
References 139
G
List of Figures
Figure Figure name Page
No. No.
(1.10) (a) The influence of current on surface finish (or crater size) 13
(b) The influence of frequency of sparking on surface finish
(or crater size)
H
(3.1) CHEMER EDM machine 37
(3.11) Optical-microscope 52
(4.1) The effect of Ton and Ip on MRR at constant Toff (25 µs) for 64
transformer oil.
(4.2) The effect of Ton and Ip on EWR at constant Toff (25 µs) for 65
transformer oil.
(4.3) The effect of Ton and Ip on SR at constant Toff (25 µs) for 66
transformer oil.
(4.4) The effect of Ton and Ip on WLT at constant Toff (25 µs) for 67
transformer oil.
I
(4.5) The effect of Ton and Ip on HV at constant Toff (25 µs) for 68
transformer oil.
(4.6) The effect of Ton and Ip on MRR at constant Toff (25 µs) for 69
gas oil
(4.7) The effect of Ton and Ip on EWR at constant Toff (25 µs) for 70
gas oil
(4.8) The effect of Ton and Ip on SR at constant Toff (25 µs) for 71
gas oil
(4.9) The effect of Ton and Ip on WLT at constant Toff (25 µs) for 72
gas oil
(4.10) The effect of Ton and Ip on HV at constant Toff (25 µs) for 73
gas oil
(4.11) The effect of Ton and Ip on MRR at constant Toff (25 µs) for 74
kerosene
(4.12) The effect of Ton and Ip on EWR at constant Toff (25 µs) for 75
kerosene
(4.13) The effect of Ton and Ip on SR at constant Toff (25 µs) for 76
kerosene
(4.14) The effect of Ton and Ip on WLT at constant Toff (25 µs) for 77
kerosene
(4.15) The effect of Ton and Ip on HV at constant Toff (25 µs) for 78
kerosene
(4.16) The effect of Ton and Ip on MRR at constant Toff (25 µs) for 79
vegetable oil.
(4.17) The effect of Ton and Ip on EWR at constant Toff (25 µs) for 80
vegetable oil.
J
(4.18) The effect of Ton and Ip on SR at constant Toff (25 µs) for 81
vegetable oil.
(4.19) The effect of Ton and Ip on WLT at constant Toff (25 µs) for 82
vegetable oil.
(4.20) The effect of Ton and Ip on HV at constant Toff (25 µs) for 83
vegetable oil.
(4.26) The normal probability plots of residuals for MRR for: (a) 93
Transformer oil (b) gas oil (c) kerosene, and (d) vegetable
oil
K
(4.30) Comparison of experimented and predicted MRR values for 95
vegetable oil
(4.31) The normal probability plots of residuals for EWR for 102
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d)
vegetable oil
L
(4.41) The normal probability plots of residuals for WLT for 120
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d)
vegetable oil.
M
List of Tables
Table Table name Page
No.
No.
N
(4.2) The experiments results 57
O
(4.18) Model summary for MRR for gas oil 99
(4.22) Values of experimented and predicted EWR for gas oil 100
P
(4.35) Values of experimented and predicted SR for kerosene 110
(4.46) Values of experimented and predicted WLT for gas oil 118
Q
(4.53) Model summary for WLT for transformer oil 125
R
List of Abbreviations
Abbreviation Description Unit
DC Direct Current A
SR Surface Roughness µm
HV Micro-Hardness kg/mm2
S
TWR Tool wear rate g/min or
mm3/min
List of Symbols
Symbol Description Unit
Br Brass ---
Cu Copper ---
Ip Current A
T
NC Numerical Control ---
V Voltage V
U
Density g/mm3
P Applied load N
D impression diagonals mm
JD jumping distance mm
V
Chapter one Principle of EDM
EDM technology is increasingly being used in tool, die and mould making
industries, for machining heat treated tool steels and advanced materials (super
alloys, ceramics and metal matrix composites) requiring high precision,
complex shapes and high surface finish. Traditional machining technique is
often based on the material removal using tool material harder than work
material. Heat treated tool steel has proved to be extremely difficult-to-machine
using traditional processes, due to rapid tool wear, low machining rates,
inability to generate complex shapes and imparting better surface finish [1]. Fig.
(1.1) illustrates examples of work produced by EDM.
New developments in the field of material science have led to new engineering
metallic materials, composite materials and high technology ceramics, with
-1-
Chapter one Principle of EDM
The EDM process involves two phases, rough machining and finish
machining. Rough machining phase requires high machining efficiency with a
certain surface quality, while the finish- machining phase requires high surface
quality. In rough machining phase, the material is removed at a faster rate
irrespective of the surface quality [3]. Due to the faster material removal from
the workpiece, the material debris gathers in the narrow discharge gap which
leads to abnormal discharges like “arcing”. Arcing is a series of discharge that
strike repeatedly on the same spot [4]. There are several types of machines and
industrial applications that employ the EDM process for high precision
machining of metals. The two primary types of EDM systems are "Die-Sinking"
and "Wire" EDM. Die-Sinking machines are also called Sinker, Ram-Type,
Conventional, Plunge or Vertical EDM. Die-sinking type EDM machines
require the electrode to be machined in the exact opposite shape as the one in
-2-
Chapter one Principle of EDM
the workpiece see Fig. (1.2). Die-sinking EDM machines use hydrocarbon oil
in which the workpiece is submersed and will be subjected to sparking upon
power discharge [5-6].
-3-
Chapter one Principle of EDM
between the workpiece and tool [10], which generates a track for each discharge
where the liquid becomes ionized in the gap, as shown in Fig.(1.3-b).
Fig. (1.3) Electrical discharge machining (EDM) (a) general setup (b) close-up
view of gap, showing discharge and material removal [9].
the spark may rise up to 10000 ºC causing to melt and vaporize the workpiece
and finally to take the shape of sphere before quenched by the fluid medium.
Higher gap despite it increases the energy of discharge, but it decreases
frequency of spark. This is due to an increase in the charging time of the
capacitor. A servo-control unit is used to sense a previous gap voltage compare
it with a used value in order to keep a previously identified gap. The difference
in voltage is used for setting the gap by controlling the servomotor movement,
as shown in Fig. (1.4) [10].
-5-
Chapter one Principle of EDM
filled with a dielectric fluid; a depth of at least (50mm) over the work surface is
maintained to eliminate the risk of fire. The tool and workpiece are connected
to a pulsating power supply. Dielectric fluid is circulated under pressure by
pump, as shown in Fig. (1.5) [11]. The mechanism of material erosion basically
uses the electrical energy and converts it into thermal energy by a series of
intermittent electrical discharges that occur between the workpiece and
electrode tool submerged in a dielectric liquid. The thermal energy creates a
plasma channel between the anode and cathode [12, 13].
-6-
Chapter one Principle of EDM
approximately 20 - 30 (KHZ) [14, 15]. The erosion of the spark of the work
material makes the use of electrical energy, converted into thermal energy
through a series of repetitive electrical discharges between the tool electrode
and the work material electrode. The thermal energy creates a plasma channel
between the two electrodes, at a temperature ranging from (8000 - 12,000) °C,
and high up to 20,000 °C. This heat causes some portion of the surrounding
dielectric fluid to evaporate; it additionally melts and vaporizes the metal to
form a small hole on the work surface as shown in Fig.(1.6)[16]. Since the spark
always occurs between the tool points and the workpiece closest together, the
high points of the workpiece are gradually eroded. Where the dielectric liquid
expels the condensed metal globules formed during the process by the flow of
the dielectric liquid. In the EDM cycle, each pulse lasts for only a few
microseconds. Pulses are repeated at rates up to 100,000 per second. These
repeated pulses lead to erosion of material from the workpiece and from the
electrode. When the process is progresses, the electrode is advanced toward the
workpiece by the servo-drive to maintain a constant gap until the completion of
the final cavity [11, 15].
-7-
Chapter one Principle of EDM
This represents the time period during which the pulse is on, it is measured
in microsecond (µs). The material removed increases when the sparking time
(pulse on time) is increased. A result, the craters will be deeper and broader.
Therefore the surface finish is rougher. While producing a better surface finish
when the shorter duration of sparks. The spark leaves the tool and hits the
workpiece which are positively charged thus producing the machining effect.
While in roughing operation, all the sparks that leave the tool result in a
microscopic removal of particles of the surface. Much more wear because of
more sparks, therefore, this operation behaves quite inverse to normal operation
in which the tool wears more during finishing than roughing [18]. Fig. (1.7)
demonstrates the effect of pulse duration on crater size increase with the
consequential increase of metal removal rate and surface roughness [19].
-8-
Chapter one Principle of EDM
Fig.(1.7) Effect of Pulse On-Time on Crater size and Surface Roughness [19].
-9-
Chapter one Principle of EDM
1.4.1.d Voltage
- 10 -
Chapter one Principle of EDM
The material is removed from both the tool and the workpiece, the (MRR)
depends on the workpiece material, as well as on the material of electrode and
the variable cutting. For example, electrode polarity, pulse conditions, and the
machining medium. In such manner, a material of low melting point has high
material removal rate, and for this reason has high surface roughness. Typical
(MRR) is from (0.1- 400) mm³/min [23].
Wbm−Wam
MRR = ……….. (1.1)
t×ρ
Where:
MRR = material removal rate (mm3/min).
Wbm = Weight of workpiece before operation (g).
Wam = Weight of workpiece after operation (g).
t = Machining time (min).
ρ = Density of workpiece material (g/mm3).
In EDM, Electrode wear is one of the most affecting factors. The change in
electrode shape by electrical sparks, electrode wear ratio can be defined as the
ratio of the amount of machining of the workpiece to the amount of electrode
- 11 -
Chapter one Principle of EDM
Ebm −Eam
EWR = × 100% …….. (1.2)
Ebm
Where:
EWR = electrode wear ratio (%).
Ebm = Weight of electrode before operation (g).
Eam = Weight of electrode after operation (g).
- 12 -
Chapter one Principle of EDM
Fig.(1.10) (a) The influence of current on surface finish (or crater size) (b) The
influence of frequency of sparking on surface finish (or crater size) [28].
Viscosity: The viscosity of the fluid is one of the most influential factors on
accuracy and finishes. In mirror finishing or close tolerance operations,
spark gaps can be as small as 0.5 or less.
Color: All dielectric oils will eventually darken with use, but it seems only
logical to start with a liquid that is as clear as possible to allow viewing of the
submerged part. Clear or “water-white” should be your choice, because any
fluid that is not clear when brand new certainly contains undesirable or
dangerous contaminants.
Odour: The oils that have a strong odour give an indication for the presence of
sulfur which is undesirable in the EDM process.
Polarity will remove material more slowly than negative polarity, but it is used
most of the time to protect the electrode from excessive wear. Negative polarity
is used for high speed metal removal when using graphite electrodes, and should
- 15 -
Chapter one Principle of EDM
- 16 -
Chapter one Principle of EDM
- 17 -
Chapter one Principle of EDM
b) Predictability of the gap-The dimensions of the gap are not always easily
predictable, especially with complex workpiece geometry.
(c) Low material removal rate-The material removal of the EDM process is
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 workpiece 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.
(d) Optimization of the electrical parameters-The choice of the electrical
parameters of the EDM process depends largely on the material combination of
electrode and workpiece and EDM manufactures only supply these parameters
for a limited amount of material combinations. When machining special alloys,
the user has to develop his own technology.
- 18 -
Chapter one Principle of EDM
5. It is used for machining sharp edges and corners that cannot be machined
effectively by other machining processes.
6. In EDM machining higher Tolerance limits can be obtained. Hence areas that
require higher surface accuracy use the EDM machining process.
- 19 -
Chapter Two Introduction and literature survey
2.1 Introduction
Kunieda M. et al. (1997) [33] in this paper, show that gas can be used
as dielectric in electric discharge machining (EDM) process, and comparison of
machining performance in air with those for EDM in liquid. The workpiece and
the electrode were made of steel and copper respectively. It was found that in
- 20 -
Chapter Two Introduction and literature survey
the case of EDM in air, the tool electrode wear ratio is much lower and the
material removal rate is much higher when the polarity of the tool electrode is
negative compared with the case in which the polarity of the tool electrode is
positive. In contrast, in the case of EDM in a liquid, there is less tool electrode
wear and higher material removal rate when the polarity of the tool electrode is
positive. The results in air show that the EWR is almost zero for any pulse-on-
time, with increasing the concentration of oxygen in air, the MRR is improved
due to heat generation caused by oxidation of the electrode materials.
- 21 -
Chapter Two Introduction and literature survey
oils are more efficient than deionized /distilled water in die sink applications.
However, water may result in higher levels of material removal rate in some
situations. Authors have studied the feasibility of adding organic compounds to
deionized water and obtained a performance higher than that of hydrocarbon
oils for roughing and finishing operations. Increase in material removal rates up
to 100% in roughing operations has been reported Water-based dielectrics can
replace hydrocarbon oils as they have higher performance and are more
environmentally suitable.
- 22 -
Chapter Two Introduction and literature survey
C. J. Luis et al. (2005) [37] studied the material removal rate (MRR)
and electrode wear (EW) on the die-sinking electrical discharge machining
(EDM) of siliconised has been carried out. This study was made only for the
final stages and has been carried out on the influence of five design factors:
intensity supplied by the generator of the EDM machine (3, 4, 5), pulse time
(30, 50, 70) μs, open-circuit voltage (-120, -160, -200) V and dielectric flushing
pressure (20, 40, 60) Kpa, over the two previously mentioned response
variables. In the research a mineral oil is used as dielectric fluid for the EDM
machine with a flash point of 82℃. The electrodes used were made of
electrolytic copper (with a cross-section of 12mm×8 mm). In the case of MRR,
the only influential design factors, for a confidence level of 95%, were: intensity
and voltage. The EWR tends to decrease with flushing pressure of dielectric is
increased.
- 23 -
Chapter Two Introduction and literature survey
much less in the white layer of the samples machined in deionized water
dielectric liquid.
- 24 -
Chapter Two Introduction and literature survey
machined for 20 minutes to record the readings the obtained results evidence
that as the material removal rate is increased with increase in pulse-off-time and
peak current. Material removal rates decreased with increase in pulse on time
in case of brass electrode and decrease in cooper electrode, and it is found that
the Copper is found to be having the highest MRR as compare to Brass. The
EWR of Brass is very high and Copper has less EWR
G. Kibria. et al. (2010) [41] this study has been performed for
micro-electrical discharge machining of titanium alloy to investigate the
influence of different dielectrics such as kerosene, deionized water, boron
carbide (B4C) powder suspended kerosene, and deionized water on machining
performance characteristics such as material removal rate (MRR), tool wear rate
(TWR). The result show that the MRR and TWR are higher using deionized
water than kerosene. Also, when boron carbide-mixed dielectrics are used,
MRR is found to increase with deionized water, but TWR decreases with
kerosene dielectric, and it's found that the thickness of white layer is less on
machined surface when deionized water is used as compared to kerosene. It can
be concluded from the research investigation that there is a great influence of
mixing of boron carbide additive in deionized water dielectrics for enhancing
machining performance characteristics in micro-EDM during micro-hole
generation on Titanium alloy.
- 25 -
Chapter Two Introduction and literature survey
electrode was made up of a copper pipe with thin wall having thickness of
0.5mm.The controllable parameter are discharge current, pulse on time, and gap
voltage. The researchers work with two cases. In the first case they perform
when only kerosene was used as dielectric as medium. In the second case both
are used as dielectric medium. The result was different when executed by only
kerosene and when executed by both. When compressed air was used at that
time the material removal rate was increased and the tool wear ratio was
decrease. The same is trail for gap voltage parameter which is the most
important parameter when both liquid are used as a dielectric as compared to
discharge current and discharge current is was most important parameter when
only kerosene was used as dielectric.
Minh Dang Nguyen et al. (2012) [43] this study aims to suppress
the electrochemical reaction in die-sinking using deionized water by employing
short voltage pulse. Deionized water has been used as dielectric fluid because it
gives higher material removal rate and lower tool wear than hydrocarbon oil.
Moreover, it is a relatively low-cost and eco-friendly substance. Therefore,
deionized water tends to be more favorable for EDM. However, it causes weak
electrochemical reaction during EDM Due to its slight conductivity. The results
show that the electrochemical reaction in micro-EDM using deionized water
can be reduced by using short voltage Pulse. Pulse-on time is the main factor
that affects the electrochemical reaction rate. And it's found that the MRR of
deionized water was more than 20 times higher than MRR of EDM oil. Also,
when deionized water was used as dielectric fluid, the debris formation was
found to be less because there was no carbon decomposed from dielectric fluid.
- 26 -
Chapter Two Introduction and literature survey
- 27 -
Chapter Two Introduction and literature survey
liquid dielectrics than that in gaseous dielectrics; higher at short pulse duration
than that at long pulse duration.
- 28 -
Chapter Two Introduction and literature survey
than hydrocarbon oils when a high pulse energy range was used. With distilled
water, the machining accuracy is poor but the surface finish is better. Work
piece surface roughness is also dependent on the type of dielectric fluid. Surface
roughness produced with deionized water is generally lower than that with
hydrocarbon oils. Electric discharge machining can also be achieved with
gaseous dielectrics such as air and oxygen. It is found that gaseous dielectric
can provide higher material removal rates than that with hydrocarbon oil.
- 29 -
Chapter Two Introduction and literature survey
machining. A copper electrode tool was used to machine the holes in tool steel
workpiece with kerosene oil as dielectric. The results show that the surface
roughness increase when discharge current and pulse on time is increased while
non-significant effect was found in terms increase pulse off and gap.
- 30 -
Chapter Two Introduction and literature survey
aerospace and automotive sector. The effects of parameters such as current (6,
9, 11)A and pulse-on-time(15, 30, 45) μs on material removal rate (mm3/min),
electrode wear rate (mm3/min), and microstructures were evaluated and
comparisons were made for the accomplishment of dielectrics (kerosene and
distilled water).The results show that the material removal rate increase with
the increase of pulse-on-time and current, Higher pulse-on-time exhibited
lower EWR, however, reverse effect has been observer with higher values of
current. Kerosene as dielectric has higher MRR and lower electrode wear rate
than distilled water. It was found that the Rougher surface can be obtained with
distilled water dielectric in comparison with kerosene as illustrated by
micrographs.
- 31 -
Chapter Two Introduction and literature survey
33 Gas, air and oil with steel alloy The MRR is improved and EWR
is almost zero when using air as
dielectric
- 32 -
Chapter Two Introduction and literature survey
- 33 -
Chapter Two Introduction and literature survey
- 34 -
Chapter Two Introduction and literature survey
2.3 Objective
The aim of this thesis is to study the effect of different dielectric fluid on surface
integrity such as (MRR, EWR, SR, WLT, HV) in electrical discharge machining
(EDM) of AISI 316L stainless steel workpiece with copper electrode and find
the best dielectric fluid of transformer oil, gas oil, kerosene, and vegetable oil
(sunflower) under different pulse-on-time and current values. MRR, EWR, SR,
WLT, and HV predication will be studied using full factorial design.
- 35 -
Chapter Three Experimental Work
3.1 Introduction
- 36 -
Chapter Three Experimental Work
- 37 -
Chapter Three Experimental Work
The dielectric fluid plays a very important role in the EDM process such
as productivity (MRR, EWR, and WLT), cost and quality (SR) of the machined
parts. In addition to health, safety and environment aspects are also to be
considered. In this experimental, an attempt is made to machine stainless steel
316L using transformer oil, gas oil, kerosene, vegetable oil (sunflower), Tap
water and water cooling car as dielectric. Vegetable oil contain free fatty acids
contents less than 1% and traces of other impurities are less than 1%. The
physical properties of the transformer oil, gas oil, kerosene and vegetable oil as
dielectrics are listed in table (3.3).
Table (3.3) The physical properties of the vegetable oil, transformer oil, gas oil,
kerosene and vegetable oil.
Dielectric Density Viscosity Boiling Specific Flash
(g/cm3)at (pa.s) at point heat point
15 oC 40 oC temp(oC) (KJ=kg.K) temp(oC)
dimensions (500 x 200) mm and uniform thickness (2mm). The sheet was cut
into small pieces with dimensions (40 x 30) mm by wire EDM machine, the
shape of workpiece is shown in Fig. (3.2). The stainless steel AISI 316L is
austenitic alloy. The chemical composition for stainless steel 316L are shown
in table (3.4). These alloys contain chromium, nickel and molybdenum, the last
which improved tensile strength, resistance to pitting makes it more corrosion
resistant and rupture resistance in the high temperature. They have higher creep
resistance, excellent formability and non-magnetic alloys. Corrosion resistance
is improved, particularly against hydrochloric, sulfuric, acetic, formic acids;
acid sulfates and alkaline chlorides [54]. The sample was examined in North
American stainless (NAS) Company Results of the analysis of the chemical
composition, physical properties and mechanical properties were calculated
according to the international specifications, as shown in the Tables (3.5), (3.6)
and (3.7).
- 39 -
Chapter Three Experimental Work
40 mm
2 mm
- 40 -
Chapter Three Experimental Work
90 mm
40 mm
9 mm
- 41 -
Chapter Three Experimental Work
- 42 -
Chapter Three Experimental Work
1. S code: function S code list, S code number from (0-9). The S code (026)
has been selected.
- 43 -
Chapter Three Experimental Work
- 44 -
Chapter Three Experimental Work
The machine used for this experiments is a die sinking EDM machine called
CHMER, model (CM 323C). The EDM process is performed on stainless steel
AISI 316L workpiece which is made anode. The electrode material used is
copper tool which is cathode and also using transformer oil, gas oil, kerosene
and vegetable oil as dielectrics. The steps are as following:
- 45 -
Chapter Three Experimental Work
4. Cleaning the workpiece and electrode from the contaminants before their
weight.
5. Using the digital balance to measure the initial and final weight of the
workpiece and electrode before and after machining.
6. The electrode was put in the tool holder that makes it cathode terminal and
be sure the balance of the electrode by indicator gauge.
7. The sample was put in the workpiece holder to be fixed and makes it anode
terminal.
8. When using transformer oil must be close the dielectric fluid tank and switch
on the pump for recycling the fluid to the level at which the tool and workpiece
submerge completely.
9. When using the vegetable oil, gas and kerosene as dielectrics. In this case the
dielectric is placed in the plastic basin and used submersible motor pump for
raising and recycling the fluid to the level at which the tool and workpiece
submerge completely.
10. Setting the desired machining parameters for each experiment using the
machine window and control panel.
11. All the specimens are cut (1mm) from one side by EDM machine, where
the dimensions become (39×30×2mm).
- 46 -
Chapter Three Experimental Work
12. After the end of each experiment, the sample and electrode were cleaned
from the dielectric remains. Then their weights were measured to determine the
MRR and EWR for each experiment.
13. The data were collected and recorded from the machine window and the
digital balance.
The weight of the workpiece and electrode before and after machining was
measured with the help of an electronic weighing balance (Denver Instrument).
It is electrical instrument and it has a high precision equivalent to (0.001) g. The
measuring range is from (0.1 mg) to (210 g), the balance device is shown in Fig.
(3.5). Materials removal rate (MRR) is calculated according to the equation
(1.1) in chapter one, which depends on the weight of the workpiece before and
after machining, and also on the calculated machining time. Electrode wear ratio
is an important factor because it affects dimensional accuracy and the shape
produced. The electrode wear ratio is expressed as the difference of weight of
the electrode before and after the machining to the weight of the electrode
before machining, which is multiplied by 100% as mentioned in equation (1.2)
in chapter one.
- 47 -
Chapter Three Experimental Work
- 48 -
Chapter Three Experimental Work
1- Cutting
Cutting process was done by electric saw, cut all specimens into small
pieces with desired dimensions (1 x 1) mm and constant thickness (2mm)
from the same side that was cut in EDM machine.
2- Mounting
The mounting process is done after cutting specimens into small pieces.
The samples must be mounted by a mixture of self-curing dental base acrylic
resin as a powder with special liquid then mixing them very fast and pouring
them on the sample. The mixture is left on the sample for several minutes
until it become hard and dry, as shown in Fig (3.7)
- 49 -
Chapter Three Experimental Work
3- Grinding
Grinding process was done by a disk rotary instrument with water using
emery paper (sic) paper with varying degrees of smoothness starting from
220,320,500,800,1000, and ending in 1200, respectively. The grinding
machine (DAP-5) works at voltage (220 V) and current (3 A) is shown in
Fig. (3.8).
4- Polishing
- 50 -
Chapter Three Experimental Work
5- Etching
6- Microstructure examination
- 51 -
Chapter Three Experimental Work
- 52 -
Chapter Three Experimental Work
- 53 -
Chapter Four Results and Discussion
4.1 Introduction
This chapter presents an analysis of the relative performance of the
proposed dielectrics, such as, transformer oil, gas oil, kerosene, and vegetable
oil. Influence of using different control parameters (pulse-on-time and current)
on the output for 36 samples made of stainless steel AISI 316L as a workpiece
with uniform thickness using copper as electrode. Factorial was used to develop
a mathematical model to predict the various response properties by using the
Minitab 18 software then analysis the predicted results and compare them with
experimental values.
- 54 -
Chapter Four Results and Discussion
- 55 -
Chapter Four Results and Discussion
Table (4.1) Experimental results for MRR, EWR, SR, WLT and HV with
transformer oil.
- 56 -
Chapter Four Results and Discussion
- 57 -
Chapter Four Results and Discussion
Table (4.3) Experimental results for MRR, EWR, SR, WLT and HV with gas
oil.
- 58 -
Chapter Four Results and Discussion
- 59 -
Chapter Four Results and Discussion
Table (4.5) Experimental results for MRR, EWR, SR, WLT and HV with
kerosene.
- 60 -
Chapter Four Results and Discussion
- 61 -
Chapter Four Results and Discussion
Table (4.7) Experimental results for MRR, EWR, SR, WLT and HV with
vegetable oil
- 62 -
Chapter Four Results and Discussion
- 63 -
Chapter Four Results and Discussion
T OFF =25 µs
50
MRR (mm3/min)
40
30
Ip= 10 A
20
Ip=24 A
10
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.1) The effect of Ton and Ip on MRR at constant Toff (25 µs) for
transformer oil.
- 64 -
Chapter Four Results and Discussion
Tof f =25 µs
0.12
0.1
EWR (%)
0.08
0.06 Ip= 10 A
0.04 Ip=24 A
0.02 Ip= 50 A
0
0 50 100 150 200 250
Ton (µs)
Fig. (4.2) The effect of Ton and Ip on EWR at constant Toff (25 µs) for
transformer oil.
- 65 -
Chapter Four Results and Discussion
Tof f =25 µs
11
10
9
SR (µm)
8
Ip= 10 A
7
6 Ip=24 A
5 Ip= 50 A
4
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.3) The effect of Ton and Ip on SR at constant Toff (25 µs) for
transformer oil
- 66 -
Chapter Four Results and Discussion
Tof f =25 µs
16
15
14
13
WLT (µm)
12
11
10 Ip= 10 A
9
8 Ip=24 A
7
6 Ip= 50 A
5
4
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.4) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
transformer oil.
- 67 -
Chapter Four Results and Discussion
Tof f =25 µs
240
230
HV (kg/mm²)
220
210
200 Ip= 10 A
190 Ip=24 A
180 Ip= 50 A
170
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.5) The effect of Ton and Ip on HV at constant Toff (25 µs) for
transformer oil.
- 68 -
Chapter Four Results and Discussion
Tof f =25 μs
35
MRR (mm3/min)
30
25
20
Ip= 10 A
15
10 Ip=24 A
5 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (μs)
Fig. (4.6) The effect of Ton and Ip on MRR at constant Toff (25 µs) for
gas oil.
- 69 -
Chapter Four Results and Discussion
Tof f =25 µs
0.1
0.08
EWR (%)
0.06
0.04 Ip= 10 A
0.02 Ip=24 A
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.7) The effect of Ton and Ip on EWR at constant Toff (25 µs) for
gas oil.
μs to 200 μs. . The reason is the same as for Fig. (4.3). It can be seen that the
highest value of SR can be reached at the highest value of Ton, Ton has the least
effect on SR than effect of current. It has been observed that the SR increases
with increasing in Ip from 10 A to 50 A. This is because more discharge energy
became available at higher levels of current, and resulted in the formation of
large cracks and crater. It can be noted the maximum SR value is (13) at highest
Ton (200 μs) and highest Ip (50 A), as shown in table (4.4).
Tof f =25 µs
14
13
12
11
SR (µs)
10
9 Ip= 10 A
8
7 Ip=24 A
6 Ip= 50 A
5
4
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.8) The effect of Ton and Ip on SR at constant Toff (25 µs) for
gas oil
- 71 -
Chapter Four Results and Discussion
between tool and workpiece. Where Ip constructed the spark responsible for size
and depth of the craters. Therefore, the formation of craters will be bigger, and
will increase WLT with high heat. It can be noted the maximum WLT value is
(17.9) at highest Ton (200 μs) and highest Ip (50 A), as shown in table (4.4).
13
Tof f =25 µs
11
WLT ((µm)
9 Ip= 10 A
Ip=24 A
7
Ip= 50 A
5
3
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.9) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
gas oil.
- 72 -
Chapter Four Results and Discussion
Tof f =25 µs
230
HV (kg/mm2)
220
210
200
190 Ip= 10 A
180 Ip=24 A
170
160 Ip= 50 A
150
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.10) The effect of Ton and Ip on HV at constant Toff (25 µs) for
gas oil.
- 73 -
Chapter Four Results and Discussion
Tof f =25 µs
35
MRR (mm3/min)
30
25
20
15 Ip= 10 A
10 Ip=24 A
5
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.11) The effect of Ton and Ip on MRR at constant Toff (25 µs) for
kerosene.
- 74 -
Chapter Four Results and Discussion
Tof f =25 µs
0.08
0.07
EWR (%)
0.06
0.05
0.04 Ip= 10 A
0.03
Ip=24 A
0.02
0.01 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.12) The effect of Ton and Ip on EWR at constant Toff (25 µs) for
kerosene.
- 75 -
Chapter Four Results and Discussion
Ton =25 µs
15
14
13
12
SR (µs) 11
Ip= 10 A
10
9 Ip=24 A
8 Ip= 50 A
7
6
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.13) The effect of Ton and Ip on SR at constant Toff (25 µs) for
kerosene.
- 76 -
Chapter Four Results and Discussion
Ton =25 µs
7
6
WLT (µs)
5
4
Ip= 10 A
3
2 Ip=24 A
1 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.14) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
kerosene.
- 77 -
Chapter Four Results and Discussion
Tof f =25 µs
230
HV (kg/mm2)
220
210
200
Ip= 10 A
190
Ip=24 A
180
170 Ip= 50 A
160
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.15) The effect of Ton and Ip on HV at constant Toff (25 µs) for
kerosene.
- 78 -
Chapter Four Results and Discussion
inside the plasma channel, which finally increases the erosion of the work
material. It can be noted the maximum MRR value is (81.087 mm3/min) at
highest Ton (200 μs) and highest Ip (50), as shown in table (4.8).
Tof f =25 µs
MRR (mm3/min)
100
80
60
Ip= 10 A
40
Ip=24 A
20
0 Ip= 50 A
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.16) The effect of Ton and Ip on MRR at constant Toff (25 µs) for
vegetable oil.
- 79 -
Chapter Four Results and Discussion
Toff = 25 µs
0.06
0.05
EWR (%)
0.04
0.03 Ip= 10 A
0.02
Ip=24 A
0.01
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.17) The effect of Ton and Ip on EWR at constant Toff (25 µs) for
vegetable oil.
- 80 -
Chapter Four Results and Discussion
maximum SR value is (7.5) at highest Ton (200 μs) and highest Ip (50 A), as
shown in table (4.8).
Tof f =25 µs
8
7
SR (µs)
6
Ip= 10
5 A
Ip=24 A
4
3
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.18) The effect of Ton and Ip on SR at constant Toff (25 µs) for
vegetable oil.
- 81 -
Chapter Four Results and Discussion
high heat. It can be noted the maximum WLT value is (9.5) at highest Ton (200
μs) and highest Ip (50 A), as shown in table (4.8).
Tof f =25 µs
20
18
WLT (µm) 16
14
Ip= 10 A
12
10 Ip=24 A
8 Ip= 50 A
6
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.19) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
vegetable oil.
- 82 -
Chapter Four Results and Discussion
(245.9 Kg/mm²) at highest Ton (200 μs) and highest Ip (50 A), as shown in table
(4.8).
T of f =25 µs
260
HV (kg/mm²) 250
240
230
220
210
Ip= 10 A
200
190 Ip=24 A
180
170 Ip= 50 A
160
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.20) The effect of Ton and Ip on HV at constant Toff (25 µs) for
vegetable oil.
4.8.1 Analysis MRR for transformer oil, gas, kerosene and vegetable oil
The material removal rate comparison for transformer oil, gas oil, kerosene
and vegetable oil is shown in Fig.(4.21). It is observed that in the case of
vegetable oil as dielectric, the MRR is the highest value in vegetable oil
followed by transformer oil and gas. However, it is noted that MRR in the case
of gas is slightly better than that of kerosene. The average relative performance
of vegetable oil, transformer oil and gas oil resulted in approximately 163% ,
52% and 5% higher MRR, respectively, compared to kerosene at higher Ton
- 83 -
Chapter Four Results and Discussion
(200 µs) and higher value of Ip (50 A). The viscosity of EDM dielectric affects
its ability to flush away debris and dissipate heat. A relatively low viscosity
results in better flushing and more effective heat dissipation. For dielectric with
high viscosity, which can restrict the expansion of the discharge channel, the
impulsive force is concentrated within a very small area. Therefore, the removal
effect is enhanced and more debris can be repelled from the crater. Since the
viscosity of vegetable oil is much larger than that of transformer oil, gas oil and
kerosene, the craters obtained in vegetable oil should be bigger and deeper than
those obtained in kerosene. In addition, vegetable oil has a higher dielectric
strength that contributes for higher discharge energy density due to higher
breakdown voltage, which leads to higher molten volume of workpiece. In
kerosene, even though viscosity is less, which is essential for flushing the
debris, high discharge temperature decomposes the kerosene, causing carbon
elements to adhere to the electrode surface, thereby causing lower MRR. Hence,
MRR becomes less in comparison with vegetable oil, transformer oil and gas.
It can be observed from the fig.(4.21) that there is a correlation between gas oil
and kerosene, which is because the value of the viscosity is almost equal to both.
- 84 -
Chapter Four Results and Discussion
Fig. (4.21) Material removal rate comparison between transformer oil, gas oil,
kerosene and vegetable oil.
4.8.2 Analysis EWR for transformer oil, gas oil, kerosene and vegetable oil
The electrode wear rate comparison for transformer oil, gas oil, kerosene
and vegetable oil is shown in Fig.(4.22). It is observed that in the case of
vegetable oil as dielectric, the EWR is the lowest value in vegetable oil followed
by kerosene and gas oil. However, it is noted that EWR in the case of gas oil is
much less than that of transformer oil. The average relative performance of
vegetable oil, kerosene and gas oil resulted in approximately 48% , 30% and
26% lower EWR, respectively, compared to transformer oil at higher Ton (200
µs) and higher value of Ip (50 A). The resulted lower EWR in the case of
vegetable oil and kerosene may be due to the deposited carbon layer on the
electrode surface that could have eroded lesser electrode material. Nevertheless,
in transformer oil, oxide layer is deposited at electrode surface which breaks
easily even at lower temperatures which consequently results in higher EWR.
- 85 -
Chapter Four Results and Discussion
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
0 1 2 3 4 5 6 7 8 9 10
Experiment number (no.)
Fig. (4.22) Electrode wear rate comparison between transformer oil, gas oil,
kerosene and vegetable oil.
4.8.3 Analysis SR for transformer oil, gas oil, kerosene and vegetable oil
The surface roughness comparison for transformer oil, gas oil, kerosene and
vegetable oil is shown in Fig.(4.23). It is observed that in the case of vegetable
oil as dielectric, the SR is the lowest value in vegetable oil followed by
transformer oil and gas oil. However, it is noted that SR in the case gas slightly
better than that of kerosene. The average relative performance of vegetable oil,
transformer oil and gas oil resulted in approximately 47% , 27 % and 9 % lower
SR, respectively, compared to kerosene at higher Ton (200 µs) and higher value
of Ip (50 A). Owing to its greater viscosity, the vegetable oil had higher flash
point and boiling point than transformer oil, gas oil and kerosene. This
characteristics weakened the capacity of the vegetable oil for heat transmission
and caused the minimal temperature difference in the workpiece. As a result,
- 86 -
Chapter Four Results and Discussion
the influence of the thermal cycling stress on the workpiece was relatively
small, and the micro-cracks produced on the surface were few and fine. The
viscosity of kerosene is lowered almost 13 to 14 times that of vegetable oil and
also has a very low flash point and boiling point. Which produces a cloud of
vapors and bubbles at low temperatures. Which eliminates fluid action and
becomes like welding process, thus producing more cracks on the surface.
15
14
13
12
11
SR (µm)
10
9
8
7
6
5
4
3
2
0 1 2 3 4 5 6 7 8 9 10
Experiment number(no.)
Fig. (4.23) Surface roughness comparison between transformer oil, gas oil,
4.8.4 Analysis WLT for transformer oil, gas oil, kerosene and vegetable oil
The white layer thickness comparison for transformer oil, gas oil, kerosene
and vegetable oil is shown in Fig.(4.24). It is observed that in the case of
kerosene as dielectric, the WLT is the lowest value in kerosene followed by gas
oil, transformer oil and vegetable oil. The average relative performance of
kerosene, gas oil and transformer oil resulted in approximately 62%, 28% and
- 87 -
Chapter Four Results and Discussion
14% lower WLT, respectively, compared to vegetable oil at higher Ton (200 µs)
and higher value of Ip (50 A). This phenomenon is explained by the fact that the
amount of molten metal that can be flushed away by different dielectrics is
different. Therefore, as vegetable oil emulsion has higher viscosity than
kerosene, it cannot clear away the molten material, and so it builds up on the
surface of the sample. During subsequent cooling, this molten material
resolidifies to form the white layer, the depth of which depends on the volume
of molten material that was left on the sample surface during machining.
Standard deviations for measured white layer thicknesses indicate that
increasing the discharge energy increases the white layer thickness deviation
considerably. It can be observed from the Fig. (4.24) the correlation of vegetable
oil at some points with transformer oil due to the high cooling rate of the
transformer oil.
8
6
4
2
0
0 1 2 3 4 5 6 7 8 9 10
Experiment number (no.)
Fig. (4.24) White layer thickness comparison between transformer oil, gas oil,
kerosene and vegetable oil.
- 88 -
Chapter Four Results and Discussion
4.8.5 Analysis HV for transformer oil, gas oil, kerosene and vegetable oil
The micro-hardness comparison for transformer oil, gas oil, kerosene and
vegetable oil is shown in Fig.(4.25). It is observed that in the case of kerosene
as dielectric, the HV is the highest value in vegetable oil followed by
transformer oil, gas oil and kerosene. The average relative performance of
vegetable oil, transformer oil and gas oil resulted in approximately 11%, 2%
and 0.5% higher HV, respectively, compared to kerosene for the same set of
parameters. The high cooling rate is the reason for the hardness increase of the
white layer when machining performed in vegetable oil, since the high cooling
rate can make the white layer freeze into a martensitic- austenitic structure
which is also known to give a high hardness. On the other hand, vegetable oil
contains the nitrogen atoms, which are carried out to the surface of the
workpiece forming solid solution. Where nitrogen atoms contribute to give a
high hardness of the surface (Nitriding). In general, the hardness increases
slightly because the metal used in machining is stanless steel 316L.
250
240
230
HV (kg/mm2)
220
210
200
190
180
170
160
150
0 1 2 3 4 5 6 7 8 9 10
Expermental number (no.)
- 90 -
Chapter Four Results and Discussion
Table (4.9) Values of experimented and predicted MRR for transformer oil.
Table (4.10) Values of experimented and predicted MRR for gas oil.
No. of Measured MRR Predicted MRR Residual
exp. values(mm³/min) values(mm3/min) values
- 91 -
Chapter Four Results and Discussion
Table (4.12) Values of experimented and predicted MRR for vegetable oil.
No. of Measured MRR Predicted MRR Residual
exp. values values (mm3/min) values
(mm³/min)
- 92 -
Chapter Four Results and Discussion
(a) (c)
(b) (d)
Fig. (4.26) The normal probability plots of residuals for MRR for: (a)
Transformer oil (b) gas oil (c) kerosene, and (d) vegetable oil.
- 93 -
Chapter Four Results and Discussion
50
45
40
MRR (mm3/min)
35
30
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9
Experiment number
35
30
MRR (mm3/min)
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.28) Comparison of experimented and predicted MRR values for gas
oil.
- 94 -
Chapter Four Results and Discussion
35
30
MRR (mm3/min)
25
20
15
10
0
1 2 3 4 5 6 7 8 9
-5
Experiment number
90
80
70
MRR (mm3/min)
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9
determine whether the factors are significantly related to the response, as shown
in tables [(4.13)-(4.16)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
Total 8 1134.42
Total 8 725.09
- 96 -
Chapter Four Results and Discussion
Total 8 4632.2
Total 8 883.73
- 97 -
Chapter Four Results and Discussion
has been obtained in regression equations for transformer oil, gas oil, kerosene,
vegetable oil as shown in equations of [(4.1)-(4.4)].
MRR1 = 27.133 - 4.12 Ton (50) + 0.75 Ton (100) + 3.37 Ton (200) - 13.12 Ip
(10) + 0.19 Ip (24) + 12.93 Ip (50) ……………… (4.1)
MRR2= 15.540 - 2.29 Ton (50) - 0.87 Ton (100) + 3.16 Ton (200) - 9.60 Ip (10)
- 1.58 Ip (24) + 11.18 Ip (50) ..………………(4.2)
MRR3= 12.807 - 3.43 Ton (50) + 0.43 Ton (100) + 3.00 Ton (200) - 9.54 Ip (10)
- 3.14 Ip (24) + 12.68 Ip (50) ………………… (4.3)
MRR4 = 37.65 - 10.64 Ton (50) + 1.00 Ton (100) + 9.64 Ton (200) - 21.83 Ip
(10) - 5.92 Ip (24) + 27.75 Ip (50) ………………… (4.4)
- 98 -
Chapter Four Results and Discussion
- 99 -
Chapter Four Results and Discussion
Table (4.21) Values of experimented and predicted EWR for transformer oil.
No. of Measured Predicted Residual
exp. EWR (%) EWR (%) values
- 100 -
Chapter Four Results and Discussion
- 101 -
Chapter Four Results and Discussion
(a) (c)
(b) (d)
Fig. (4.31) The normal probability plots of residuals for EWR for (a)
transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.
- 102 -
Chapter Four Results and Discussion
0.14
0.12
0.1
0.08
EWR (%)
0.06
0.04
0.02
0
-0.02 1 2 3 4 5 6 7 8 9
Experimented number
0.09
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
-0.01 1 2 3 4 5 6 7 8 9
-0.02
Experiment number
Fig. (4.33) Comparison of experimented and predicted EWR values for gas
oil.
- 103 -
Chapter Four Results and Discussion
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
-0.01 1 2 3 4 5 6 7 8 9
Experimented number
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
1 2 3 4 5 6 7 8 9
Experiment number
in tables [(4.25)-(4.28)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
Total 8 0.012496
Total 8 0.0070
- 105 -
Chapter Four Results and Discussion
Total 8 0.0049
Total 8 4632.2
EWR1 = 0.05748 + 0.01962 Ton (50) - 0.00234 Ton (100) - 0.01728 Ton (200)
- 0.04471 Ip (10) + 0.00772 IP (24) + 0.03699 IP (50) ………….. (4.5)
EWR2 = 0.03414 + 0.01459 Ton (50) - 0.00404 Ton (100) - 0.01054 Ton (200)
- 0.03084 Ip (10) + 0.00026 Ip (24) + 0.03059 Ip (50) …………. (4.6)
EWR3 = 0.03318 + 0.01327 Ton (50) - 0.00705 Ton (100 )- 0.00622 Ton
(200)- 0.02738 Ip (10) + 0.00539 Ip (24) + 0.02199 Ip (50) …………. (4.7)
- 107 -
Chapter Four Results and Discussion
- 108 -
Chapter Four Results and Discussion
- 109 -
Chapter Four Results and Discussion
- 110 -
Chapter Four Results and Discussion
(a) (c)
(b) (d)
Fig. (4.36) The normal probability plots of residuals for SR for (a)
transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.
- 111 -
Chapter Four Results and Discussion
Experimented SR Predicted SR
12
10
8
SR (µm)
6
0
1 2 3 4 5 6 7 8 9
Experiment number
Experimented SR Predicted SR
14
12
10
SR(µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.38) Comparison of experimented and predicted SR values for gas oil.
- 112 -
Chapter Four Results and Discussion
Experimented SR Predicted SR
16
14
12
SR(µm) 10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Experimented SR Predicted SR
16
14
12
10
SR (µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
- 113 -
Chapter Four Results and Discussion
Total 8 26.940
Total 8 52.440
- 114 -
Chapter Four Results and Discussion
Total 8 54.229
Total 8 87.56
- 115 -
Chapter Four Results and Discussion
SR1 = 6.500 - 1.600 IP (10) - 0.433 IP (24) + 2.033 IP (50) ...…… (4.9)
SR2 = 8.067 - 2.700 IP (10) - 0.033 IP (24) + 2.733 IP (50) ……. (4.10)
SR3 = 9.911 - 0.878 Ton (50) - 0.044 Ton (100) + 0.922 Ton (200) - 2.844 IP (10)
+ 0.022 IP (24) + 2.822 IP (50) …… (4.11)
SR4 = 6.267 - 2.57 IP (10) - 0.80 IP (24) + 3.37 IP (50) ……… (4.12)
- 116 -
Chapter Four Results and Discussion
- 117 -
Chapter Four Results and Discussion
Table (4.45) Values of experimented and predicted WLT for transformer oil.
No. of Measured WLT Predicted WLT Residual
exp. values(µm) values(µm) values
- 118 -
Chapter Four Results and Discussion
- 119 -
Chapter Four Results and Discussion
(a) (c)
(b) (d)
Fig. (4.41) The normal probability plots of residuals for WLT for
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.
- 120 -
Chapter Four Results and Discussion
16
14
WLT (µm) 12
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experimentel number
14
12
10
WLT (µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.43) Comparison of experimented and predicted WLT values for gas oil.
- 121 -
Chapter Four Results and Discussion
7
6
5
WLT(µm) 4
3
2
1
0
1 2 3 4 5 6 7 8 9
Experiment number
16
14
12
WLT (µm)
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experimentel number
- 122 -
Chapter Four Results and Discussion
determine whether the factors are significantly related to the response, as shown
in Tables [(4.49)-(4.52)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
6 17.43 2.904
Error
8 97.59
Total
Total 8 82.4400
- 123 -
Chapter Four Results and Discussion
Total 8 41.2756
Total 8 118.659
WLT1 = 10.989 - 3.922 IP (10) + 0.611 IP (24) + 3.311 IP (50) ………. (4.13)
WLT2 = 8.2000 - 0.767 Ton (50) + 0.167 Ton (100) + 0.600 Ton (200) - 3.567 IP
(10) - 0.133 IP (24) + 3.700 IP (50) ……….. (4.14)
WLT3 = 3.422 - 0.722 Ton (50) + 0.111 Ton (100) + 0.611 Ton (200) - 2.622 IP
(10)+ 0.244 IP (24)+ 2.378 IP (50) ……….. (4.15)
WLT4 = 11.978 - 1.078 Ton (50)- 0.044 Ton (100)+ 1.122 Ton (200)- 4.678 IP
(10)+ 0.922 IP (24)+ 3.756 IP (50) ………. (4.16)
- 125 -
Chapter Four Results and Discussion
- 126 -
Chapter Four Results and Discussion
- 127 -
Chapter Four Results and Discussion
- 128 -
Chapter Four Results and Discussion
(a) (c)
(b) (d)
Fig. (4.46) The normal probability plots of residuals for HV for
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.
- 129 -
Chapter Four Results and Discussion
Experimented HV Predicted HV
250
200
HV (kg/mm2) 150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
Experimented HV Predicted HV
250
200
HV (kg/mm2)
150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.48) Comparison of experimented and predicted HV values for gas oil.
- 130 -
Chapter Four Results and Discussion
Experimented HV Predicted HV
250
200
HV (kg/mm2) 150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
300
250
HV (kg/mm2)
200
150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
- 131 -
Chapter Four Results and Discussion
Total 8 2541.94
Total 8 4319.06
- 132 -
Chapter Four Results and Discussion
Total 8 2564.31
Total 8 5776.92
- 133 -
Chapter Four Results and Discussion
been obtained in regression equations for transformer oil, gas oil, kerosene,
vegetable oil, as shown in equations of [(4.17), (4.18), (4.19), and (4.20)].
HV1 = 202.944 - 5.04 Ton (50) - 0.74 Ton (100) + 5.79 Ton (200) - 20.91 IP (10)
+ 2.52 IP (24) + 18.39 IP (50) …………. (4.17)
HV2 = 188.78 - 6.31 Ton (50) + 0.89 Ton (100) + 5.42 Ton (200) - 28.24 IP (10)
+ 5.49 IP (24) + 22.76 IP (50) …………. (4.18)
HV3 = 193.889 - 4.06 Ton (50) - 0.52 Ton (100) + 4.58 Ton (200) - 21.22 IP (10)
+ 2.48 IP (24) + 18.74 IP (50) ………..... (4.19)
HV4 = 205.70 - 7.80 Ton (50) - 1.90 Ton (100) + 9.70 Ton (200) - 31.33 IP (10)
+ 3.83 IP (24) + 27.50 IP (50) ………….. (4.20)
- 134 -
Chapter Four Results and Discussion
- 135 -
Chapter Five Conclusions and Recommendations
5.1 Introduction
5.2 Conclusions
1. The MRR of ASTM stainless steel 316L for vegetable oil, transformer oil
and gas oil as dielectric resulted in 163%, 52% and 5% higher MRR,
respectively, than kerosene at higher Ton (200 µs) and higher value of IP
(50 A).
2. Vegetable oil showed lower EWR than others dielectrics, the average
relative performance of vegetable oil, kerosene and gas oil resulted in
48%, 30% and 26% lower EWR than transformer oil at higher Ton (200
µs) and higher value of IP (50 A).
3. The SR in vegetable oil, transformer oil, gas oil produced 47%, 27%, and
9% lower SR, respectively than kerosene at higher Ton (200 µs) and higher
value of IP (50 A).
4. The white layer thickness is thin for kerosene than vegetable oil, the
average relative performance of kerosene gas oil and transformer oil
resulted in approximately 62%, 28% and 14% lower WLT, respectively,
- 136 -
Chapter Five Conclusions and Recommendations
compared to vegetable oil at higher Ton (200 µs) and higher value of IP (50
A).
5. The micro-hardness is greater for vegetable oil than others dielectrics due
to the high cooling rate is the reason for the hardness increase of the white
layer when machining performed in vegetable oil.
6. The average relative performance of vegetable oil, transformer oil, and
gas oil resulted in 11%, 2% and 0.5% higher HV, respectively, than
kerosene at higher Ton (200 µs) and higher value of IP (50 A).
7. When increasing the pulse-on-time and current, the material removal rate,
surface roughness, white layer thickness and micro-hardness are
increased.
8. Higher pulse-on-time exhibited lower EWR, however, reverse effect has
been observed with higher values of current.
9. Vegetable oil emanate lesser smoke and fewer odours and use of vegetable
oil as dielectric increase the productivity. In addition, the environmental
hazard of vegetable oil are lower.
10.From the software, the results revealed that the Factorial model can predict
the machining responses with a good accuracy of (R-sq=97.42 %) for
MRR at transformer oil, (R-sq = 98.82 %) for EWR at transformer oil, (R-
sq = 97.80%) for SR at kerosene, (R-sq =99.73%) for WLT at vegetable
oil, and (R-sq = 99.25 %) for HV at vegetable oil.
- 137 -
Chapter Five Conclusions and Recommendations
- 138 -
Haneen Lateef Abdulwahhab. Study the effect of different dielectric fluid on
surface integrity for electrical discharge machining (EDM). University of
Technology/ Department of Production Engineering and Metallurgy. M.SC.
Supervised: Asst. prof. Dr. Shukry Hammed Aghdeab 2019, 182
Abstract
This thesis aims to investigate the effect of using different dielectric liquids
including transformer oil, gas oil, kerosene and vegetable oil (sunflower) on the
material removal rate (MRR), electrode wear ratio (EWR), surface roughness
(SR), white layer thickness (WLT), and micro-hardness (HV) in EDM. Pulse-
and current of (10, 24, 50) A have been chosen as on-time of (50, 100, 200) µs
input parameters. Machining was carried out on stainless steel AISI 316L
specimens with a copper electrode. The factorial design was used to develop
mathematical models for each dielectric fluid to create plots to determine the
(MRR, EWR, SR, WLT and HV) performance with increasing pulse-on-time
(T on ) and current(I p ). The results show that the vegetable oil can be used as
lower EWR, best SR and high HV ،dielectric in EDM, it gives highest MRR
when compared to transformer oil, gas oil, and kerosene. Analysis of variance
results indicate that the pulse-on-time and current are the most important factors.
The MRR in vegetable oil, transformer oil, gas oil produced 163%, 52%, and
5% higher MRR, respectively, than kerosene and MRR increases with increase
in T on and I P . The EWR in vegetable oil, kerosene, gas oil resulted in 48%, 30%,
R R R R
and 26% lower EWR than transformer oil, EWR decreases with increase in T on R
R but increases with increase in I P . The SR in vegetable oil, transformer oil, gas oil
R R
produced 47%, 27%, and 9% lower SR, respectively than kerosene. In addition,
The WLT in kerosene, gas oil and transformer oil resulted in approximately
62%, 28% and 14% lower WLT, respectively, compared to vegetable oil. The
HV in vegetable oil, transformer oil, and gas oil resulted in 11%, 2% and 0.5%
higher HV, respectively, than kerosene. The SR, WLT, and HV increases with
increasing T on and I P .
REFERENCE
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References
- 146 -
CHAPTER TWO
INTRODUCTION AND
LITERATURE SURVEY
CHAPTER ONE
PRINCIPLES OF EDM
CHAPTER THREE
EXPERIMENTAL WORK
CHAPTER FOUR
RESULTS AND
DISCUSSION
CHAPTER FIVE
CONCLUSIONS AND
RECOMMENDATIONS
FOR FUTURE WORK
REFERENCES
المستخلص
يهدف هذا البحث الى دراسة تاثير استخدام سوائل عازلة مختلفة بما في ذلك زيت المحوالت,
زيت الكاز ,الكيروسين ,و الزيت النباتي على معدل ازالة المادة ) ,(MRRمعدل بلى القطب ),(EWR
الخشونة السطحية ( ,(SRوسمك الطبقة البيضاء ( ,(WLTوالصالدة ) (HVفي . EDMزمن النبضة
ذو القيمة ( )055 ,055 ,05مايكروثانية والتيار ( )05 , 02 ,05أمبير تم اختياره كمدخالت ,تم تنفيذ
التشغيل على الفوالذ المقاوم للصدأ AISI 603Lمع قطب النحاس .تم استخدام التصميم فاكتوريال
لتطوير موديالت رياضية لكل عازل من اجل انشاء مخططات لتحديد كيفية أداء (SR ,EWR , MRR
WLT ,و )HVمع زيادة زمن النبضة والتيار .أظهرت النتائج ان الزيت النباتي يمكن استخدامه كعازل
في , EDMفهو يعطي أعلى , MRRواقل , EWRافضل , SRواعلى HVبالمقارنة مع زيت
المحوالت ,زيت الكاز ,والكيروسين .واظهرت نتائج تحليل التباين الى ان التيار وزمن النبضه هما اهم
العوامل المؤثره على .HV ,WLT ,SR ,EWR ,MRRمعدل ازاله المادة ) (MRRفي الزيت
النباتي ,زيت المحوالت ,زيت الكاز تنتج %0 ,%00 ,%036اعلى ,MRRعلى التوالي مقارنة
بالكيروسين و MRRتزداد عند زيادة Tonو .IPمعدل البلى للقطب في الزيت النباتي ,الكيروسين ,الكاز
ينتج بنسبة %03 ,%65 , %24اقل EWRمقارنة بزيت المحوالت ,تقل EWRعند زيادة Tonولكن
تزداد مع زيادة . IPالخشونة السطحية في الزيت النباتي ,زيت محوالت ,زيت الكاز تنتج ,%04, %24
%9اقل SRعلى توالي ,مقارنة بالكيروسين .بينما الكيروسين ,زيت الكاز ,زيت المحوالت ينتج تقريبآ
%02 ,%04 ,%30اقل WLTعلى التوالي مقارنة بالزيت النباتي .معدل االداء النسبي لزيت النباتي
,زيت المحوالت ,زيت الكاز ينتج %5.0 ,%0 ,%00اعلى HVعلى التوالي مقارنة بالكيروسين.
. IP ال WLT, ,SRو HVتزداد مع زيادة كل من Tonو
جمهورية العراق
الجامعة التكنولوجية
رسالة مقدمة إلى قسم هندسة اإلنتاج والمعادن في الجامعة التكنولوجية وهي جزءا
من متطلبات نيل درجة الماجستير في علوم هندسة اإلنتاج
قد َمتها
حنين لطيف عبدالوهاب
بإشراف
أ.م .د .شكري حميد غضيّب
2019ميالدي 1440هجري