EFFECT OF MACHINING PARAMETRS ON

METAL REMOVAL RATE DURING ELECTRIC

DISCHARGE DRILLING OF Al 6061 WITH
HOLLOW Cu ELECTRODE

Under Guidance of
Presented by
Dr Rajesh Choudhary Gagandeep Singh Bagga
HOD, MIMIT Research Scholar, MIMIT
Malout Malout

4/11/17 1
 Plan of Presentation

1. Introduction
2. Experimental Details
.DOE (Design of Experiments)
.Rotary attachment of EDD
3. Results and discussions
4. Conclusions
5. References

4/11/17 2
 Introduction

EDM, an un-conventional machining process used to machine

hard to machine alloys.
Electric discharge machining techniques have been improved
such improved method is one Electric Discharge Drilling
(EDD).
EDD uses the same principles as EDM to erode material over
the surface of material with only difference the electrode is
given rotation in EDD.
The rotation of the tool electrode favors clean cuts and
reduces under-cutting.
4/11/17 3
 Contd..
EDD is carried out producing
minute holes with
machining time ranging
from 7-10 mins.
Experiments performed with
low current value and higher
machining time resulted in
Fig. 1. Schematic setup of
through holes. EDD [1].
1.Control Panel 7.Base 13.Motor
2.Vice 8.Dielectric 14.Servo system
3.Work piece 9.Stirrer 15.V-belt

Both electrode and work- 4.Tool Holder

5.Dielectric fluid
6.Dielectric pump
10.Bearing
11.Shaft casing
12.Al plate
16.V-pulley
17.Chuck nut

piece are immersed in

dielectric fluid and
4/11/17 4
 Experimental Details
Aluminium alloy 6061, two Table 1. Chemical
Composition of Alloy
slabs of dimensions (50*75*6) Element 6061Composition
mm were used to drill holes. (%)
Aluminium 95.8598.56
Tool used was hollow copper Magnesium 0.8-1.2
tube (2mm dia) with normal Silicon 0.4-0.8
Iron 0.7 max
flow of di-electric fluid. Copper 0.15-0.4
Applications of this alloy in Manganese 0.15 max
Chromium 0.04-0.35
construction of aircraft Zinc 0.25 max
structures, automotive parts, Titanium 0.15 max
Other elements 0.05
military tanks, weapons max
production, for making cans
for packaging of beverages.
4/11/17 5
 Contd..

Machining Parameters in an EDD process are of two

types: Non Electrical
Electrical Parameters Parameters
Pulse on time, Pulse of time Flushing pressure

Peak current, Gap voltage

Tool Polarity
Pulse on-time, Pulse off-time, Gap voltage and Tool
polarity were control parameters whereas MRR was
Response parameter in this study. Taguchi method was
employed to Design experiments based on D.O.F.
4/11/17 6
 Design Of Experiments (DOE)
The Taguchi method involves
reducing the variation in a
process through robust design
of experiments.
L18 orthogonal array was
chosen based upon specific
Parameter Unit Level 1 Level 2 Level 3
parameters
Polarity considered
+ - and
their
Current
Pulse on-time
sub-levels;
Ampere (A)
Micro-Seconds
1D.O.F. 2
10 12
3
14
(s) Fig. 2. Taguchis DOE flow
Pulse off-time Micro-Seconds 10.5 11.5 12.5 chart.
(s)

4/11/17 7
 Rotary attachment of EDDM

The rotary attachment

comprises of namely these
parts:
1.) Tool electrode, 2.) Tool
chuck, 3.) Tool holder, 4.)
DC servo motor, 5.)
Flushing pipe.
Rotary attachment was
prepared in Lab of College
Fig. 3. Rotary attachment of EDDM
and added to ram of EDM
(100 RPM).
4/11/17 8
 Results and Discussions
All the experiments
were conducted as per
DOE Taguchis L18
orthogonal Array plan
and each trial run was
conducted up to 7 min.

Taguchis method, the

deviation of quality
characteristics from the Fig. 4. Machined workpiece after EDD.
desired value is
measured using SN
4/11/17 9
 Contd..
The trail 9 with Table 2. Experimental Results for MRR

positive tool S. no. Polarity Current

(A)
On Time
(s)
Off Time
(s)
MRR
(g/min)
polarity has the 1
2
+
+
1
1
10
12
10.5
11.5
0.0042
0.0035
highest MRR of 3
4
+
+
1
2
14
10
12.5
10.5
0.0032
0.0051
0.0098 g/min ; 5
6
+
+
2
2
12
14
11.5
12.5
0.0044
0.0038
owning to 3 A 7
8
+
+
3
3
10
12
10.5
11.5
0.0061
0.0079
Gap Current. 9
10
+
-
3
1
14
10
12.5
10.5
0.0098
0.0040
11 - 1 12 11.5 0.0034
12 - 1 14 12.5 0.0030
Signal to noise 13
14
-
-
2
2
10
12
10.5
11.5
0.0048
0.0042
ratios were also 15
16
-
-
2
3
14
10
12.5
10.5
0.0036
0.0054
considered 17
18
-
-
3
3
12
14
11.5
12.5
0.0072
0.0091
indicating
4/11/17 the 10
 Contd..
MINITAB V.17
generated the Signal
to Noise ratio plots .
To find the
significance of each
control parameter on
the MRR (Response
parameter) ANOVA
analysis was done.
Fig. 5. Main Effect Plot for SN ratio for MRR.

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 Contd..
Higher the current
higher the MRR due to
higher thermal energy
incidented on
workpiece.
Higher the pulse on-
time means higher is
the window of time
available for thermal
Fig. 6. 3-D surface plot for SN ratio for
energy to indent over MRR.
workpiece.
4/11/17 12
 Contd..
Table 3. ANOVA Table for Means

P value of current is Source DF Seq.SS Adj.SS F P Adj.M
S
minimum in ANOVA table Polarity 1 0.000 0.000 0.35 0.568 0.000
suggesting current has 001 001 001
Current 2 0.000 0.000 16.13 0.002 0.000
highest impact of the 055 055 055
Response parameter Pulse 2 0.000 0.000 0.21 0.813 0.000
on-time 001 001 001
MRR.

Pulse 2 0.000 0.000 0.56 0.591 0.000
off-time 002 002 002
Polarity* 2 0.000 0.000 0.07 0.929 0.000
P 0.5 means the current 000 000 000
parameter has highest Residua 8
l error
0.000
014
0.000
014
0.000
014
impact. Total 17 0.000
072
Current
4/11/17
has P value = 13
 Conclusions
Effect of current, pulse on time, pulse off time on material removal rate of Al
alloy 6061 is concluded. Taguchis L18 orthogonal array is used for design of
experiments. ANOVA analysis was carried out to study the Experiments Results.
Following conclusions were drawn from the study:
Drilling of Al alloy 6061 is effectively achieved sophonsifying surface finish
parameter.

Peak current influences the most- MRR followed by Pulse off-time, Pulse on-
time and Tool polarity.

Maximum MRR (0.0098g/min) was observed at 3A current, 14s pulse on

time, 12.5s pulse off time and positive tool polarity by copper tool electrode.

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 Future Scope

Scope of the study can be explored by consider the other measuring

parameters like tool rotation, speed, dia of tool electrode etc.

Some other response parameters can also be considered to show the

behavior of process as surface roughness(SR) and Tool wear rate.

Microstructural investigation can be conducted to examine the

machined surface and detection of elements and compounds
formation after machining.

4/11/17 15
 Acknowledgment

The authors of the research work deeply

acknowledge the funding given by the All India
Council for Technical Education (AICTE) New Delhi
for providing the EDM setup under MODROBS
scheme in the Department of Mechanical
Engineering at MIMIT, Malout.
4/11/17 16
 References
K.Tamil Mannan, A. Krishnaiah, S.P. Arikatla, Surface Characterization of Electric Discharge
Machined Surface of High Speed Steel, Advanced Materials Manufacturing & Characterization,
pp. 161-168, 2013.
Abhishek Singh et al. (2013) Design and Development of Electro-Discharge Drilling Process,
Advanced Materials Research Vol. 651 (2013) pp 607-611.
S. Vijaya kumar et al. (2015) Parametric Optimization of Electric Discharge Drilling Machine
Using Al-SiC Metal Matrix Composite, International Journal of Science, Engineering and
Technology Research (IJSETR), Volume 4, Issue 1.
Samar Singh et al. (2012) A Parametric optimization of electric discharge drill machine using
Taguchi approach, Journal of engineering, computer and applied sciences (JEC&AS) Volume 1,
No. 3.
Kumar Sandeep et al. (2013) Current Research Trends in Electrical Discharge Machining
Research Journal of Engineering Sciences_ISSN 2278 9472 Vol. 2(2), 56-60.
Chen et al. (2013), Application of Taguchi Design Method to Optimize the Electrical Discharge
Machining, Journal of Achievement in Materials and Manufacturing Engineering, Vol. 57/Issue
2/April2013/pp. 76-82.
A. PRAMANIK, A. K. BASAK et al. (2015) Electrical discharge machining of 6061 Aluminium
alloy, Trans. Nonferrous Met. Soc. China 25(2015) 28662874.
M. Boujelbene, E. Bayraktar, W. Tebni, S.B. Salem, Influence of machining parameters on the
surface integrity in electrical discharge machining, Archives of Materials Science and
Engineering, vol. 37, no. 2, pp. 110-116, 2009.
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