Open Access

Experimental Analysis of EDM Parameters on D2 Die Steel Using Nano-aluminum Composite Electrodes

Y. Justin Raj, Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Science (SIMATS), Chennai, TN, India A. Bovas Herbert Bejaxhin, herbert.mech2007@gmail.com
Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Science (SIMATS), Chennai, TN, India
R. Madhumitha, ECE Department, St. Joseph’s College of Engineering, Chennai, TN, India A. S. Anitha, Department of Biotechnology, Karpaga Vinayaga College of Engineering and Technology, Padalam, TN, India Hitesh Gehani, School of Computer Science & Engineering, Shri Ramdeobaba College of Engineering and Management, Ramdeobaba University, Nagpur, MH, India Aslam Abdullah , School of Chemical Engineering, Vellore Institute of Technology, Vellore, TN, V. Naveenprabhu Department of Mechanical Engineering, Sri Eshwar College of Engineering, Coimbatore, TN, India


J. Environ. Nanotechnol., Volume 13, No 3 (2024) pp. 197-206

https://doi.org/10.13074/jent.2024.06.243848

PDF


Abstract

         This paper presents an experimental study on the electrical discharge machining (EDM) of AISI D2 die steel using an Al-Ni composite electrode. The investigation focuses on the influence of input parameters like current, pulse duration, and pulse interval, on key output parameters such as material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). EDM oil was employed as the dielectric fluid. Grey relational analysis (GRA) was utilized for designing and conducting the experiments using the Taguchi L9 method. The ANN model showed excellent predictive accuracy with a perfect correlation coefficient (R) of 1.00, indicating strong capability in forecasting MRR based on machining parameters. GRA further confirmed that higher current settings and longer pulse-off times effectively reduce tool wear, suggesting that the ANN model accurately reflects the conditions that minimize TWR. The ANN model achieved strong predictive accuracy for SR, with high correlation coefficients, although with slightly higher mean squared error (MSE) in testing.

Full Text

Reference


Anbuchezhiyan, G., Saravanan, R., Pugazhenthi, R., Palani, K. and Mamidi, V. K., Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite, Adv. Mater. Sci. Eng., 2022, 1–11 (2022).

https://doi.org/10.1155/2022/9539790

Ansari, M. and Khan, I. A., Investigation on the performance of wire electrical discharge machining (WEDM) using aluminium matrix composites (AMCs) micro-channel, Eng. Res. Express, 5(3), 035065 (2023).

https://doi.org/10.1088/2631-8695/acf5ca

George, J., Chandan, R., Manu, R. and Mathew, J., Experimental Investigation of Silicon Powder Mixed EDM Using Graphene and CNT Nano Particle Coated Electrodes, Silicon, 13(11), 3835–3851 (2021).

https://doi.org/10.1007/s12633-020-00658-0

Jana, A. K., Ranjith Kumar, R., Mohanty, S. C., Mangapathi Rao, K., Shanker, V. G. and Reddy, A. Y., Parametric Optimization of Die Sinking EDM in AISI D2 Steel considering Canola oil as Dielectric using TOPSIS and GRA, IOP Conf. Ser. Mater. Sci. Eng., 1057(1), 012061 (2021).

https://doi.org/10.1088/1757899X/1057/1/012061

Jeykrishnan, J., Vijaya Ramnath, B., Chenbaga Ram, N., Naveen Babu, R. and Naveen, B., Experimental investigation on powder mixed electro - discharge machining (EDM) of D2 die steel with De-ionized water as dielectric medium, IOP Conf. Ser. Mater. Sci. Eng., 402, 012084 (2018).

https://doi.org/10.1088/1757-899X/402/1/012084

Jeykrishnan, J., Vijaya Ramnath, B., Jude Felix, A., Rupan Pernesh, C. and Kalaiyarasan, S., Parameter Optimization of Electro-Discharge Machining (EDM) in AISI D2 Die Steel using Taguchi Technique, Indian J Sci Technol.

https://doi.org/10.17485/ijst/2016/v9i43/101972

Najm, V., Abbas, T. and Aghdeab, S., Integrating Grey Relation Analysis and Artificial Neural Networks for Optimal Machining of Tungsten Carbide Composite Using Hybrid Electrochemical Discharge, Eng. Technol. J., 41(12), 1594–1610 (2023).

https://doi.org/10.30684/etj.2023.143347.1581

Naveen, S., Aravind, S., Yamini, B., Vasudhareni, R., Gopinath, K. P., Arun, J. and Pugazhendhi, A., A review on solar energy intensified biomass valorization and value-added products production: Practicability, challenges, techno economic and lifecycle assessment, J. Clean. Prod., 405, 137028 (2023).

https://doi.org/10.1016/j.jclepro.2023.137028

Naveenprabhu, V. and Suresh, M., Performance studies on a water chiller equipped with natural fiber cooling pad based evaporative condenser, Ind. Crops Prod., 201, 116923 (2023).

https://doi.org/10.1016/j.indcrop.2023.116923

Padhi, P. C. and Tripathy, D. K., Multi-response optimisation of machining parameters in wire EDM process using grey relational analysis, Int. J. Manuf. Technol. Manag., 34(4), 376 (2020).

https://doi.org/10.1504/IJMTM.2020.108019

Paswan, K., Pramanik, A., Chattopadhyaya, S., Sharma, S., Singh, G., Khan, A. M. and Singh, S., An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance, Arab. J. Sci. Eng., 48(9), 11941–11957 (2023).

https://doi.org/10.1007/s13369-023-07626-x

Pradhan, M. K. and Biswas, C. K., Neuro-fuzzy and neural network-based prediction of various responses in electrical discharge machining of AISI D2 steel, Int. J. Adv. Manuf. Technol., 50(5–8), 591–610 (2010).

https://doi.org/10.1007/s00170-010-2531-8

Priyadharsini, P., SundarRajan, P., Pavithra, K. G., Naveen, S., SanjayKumar, S., Gnanaprakash, D., Arun, J. and Pugazhendhi, A., Nanohybrid photocatalysts in dye (Colorants) wastewater treatment: Recent trends in simultaneous dye degradation, hydrogen production, storage and transport feasibility, J. Clean. Prod., 426, 139180 (2023).

https://doi.org/10.1016/j.jclepro.2023.139180

Raj, Y. J., Bejaxhin, A. B. H. and Rajkumar, S., Review about removal rates and wear rate of EDM using nano composite electrodes with variant electrolytic solutions, In: (2024).

https://doi.org/10.1063/5.0197422. p 020249

Raza, M. H., Wasim, A., Ali, M. A., Hussain, S. and Jahanzaib, M., Investigating the effects of different electrodes on Al6061-SiC-7.5 wt% during electric discharge machining, Int. J. Adv. Manuf. Technol., 99(9–12), 3017–3034 (2018).

https://doi.org/10.1007/s00170-018-2694-2

Rizwee, M., Minz, S. S., Md. Orooj, Hassnain, M. Z. and Khan, M. J., Electric Discharge Machining Method for various Metal Matrix Composite Materials, Int. J. Innov. Technol. Explor. Eng., 8(9), 1796–1800 (2019).

https://doi.org/10.35940/ijitee.I8112.078919

Sharma, A., Kumar, V., Babbar, A., Dhawan, V., Kotecha, K. and Prakash, C., Experimental Investigation and Optimization of Electric Discharge Machining Process Parameters Using Grey-Fuzzy-Based Hybrid Techniques, Materials (Basel)., 14(19), 5820 (2021).

https://doi.org/10.3390/ma14195820

Venkateswaran, N., Subbaiyan, N., Punniyakotti Varadharajan, G., Vellingiri, S., Asary, A. R., Giri, J. M. and Petchimuthu, P., A comprehensive review of the energy efficiency on nano coated fin and tube condenser, Environ. Qual. Manag., 33(1), 293–301 (2023).

https://doi.org/10.1002/tqem.22055

Y. Justin Raj, A. Bovas Herbert Bejaxhin, S. Raj Kumar and G. M. Balamurugan, Influence of Novel Al-Ni Electrodes on Roughness and Machining Time in Inconel 625 EDM Machining: A Comprehensive RSM Performance Analysis, J. Environ. Nanotechnol., 13(1), 243–253 (2024).

https://doi.org/10.13074/jent.2024.03.241547

Contact Us

Powered by

Powered by OJS