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Study focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431.
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A Study of Hole Drilling on Stainless Steel AISI 431 by EDM Using Brass Tube Electrode
Study focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431.
Study focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431.
*Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189.
xt . 3189. E-mai l addr esses:
mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 471
Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es
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A Study of Hole Drilling on Stainless Steel AISI 431 by EDM Using Brass Tube Electrode
Pichai Janmanee a , and Apiwat Muttamara a*
a Department of Industrial Engineering Faculty of Engineering, Thammasat University, THAILAND
A R T I C L E I N F O
A B S T R A C T Article history: Received 23 August 2011 Received in revised form 23 September 2011 Accepted 27 September 2011 Available online 27 September 2011 Keywords: EDM, AISI 431, Electrode, Brass, Taper When a depth hole is drilled by EDM, taper is occurred which is not desired in the process. This research was focused on influence of EDM parameters on material removal rate (MRR), electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431. The considered factors consist of electrical current, on-time, duty factor, water pressure and servo rate. The experimental results reveal that MRR increases when increasing of servo rate. The taper of hole increases with increasing of electrical current and servo rate. However, it is reverse proportion to water pressure and duty factor.
2011 Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. 1 Introduction Nowadays, stainless steel AISI 431 is a popular material used in many industries such as water pump, kitchenware, and fittings manufacturing industries(Jeong and Min, 2007). Because of its durability to environment. However, as drilling a hole on stainless steel is difficult due to its properties. Therefore, various meso or micro machining methods have been introduced, such as machining, ultrasonic, electrochemical, laser, electrical discharge machining. Especially an electrical discharge machining (EDM) is one of non-contact thermal process, which has advantages such as high-precision machining of conductive materials and 2011 Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. 472 Pichai Janmanee, and Apiwat Muttamara
insulating materials regardless of material hardness, (Muttamara et al, 2009&2010). However, the important type of defect from hole drilling during EDM process is hole taper and hole accuracy (Ali et al.2009). Therefore, in order to improve hole quality, Sharma et al.(2002) and Bilgi et al.(2007) investigated optimum values of the process parameters experimentally such as voltage, feed rate, pulse on time, duty cycle, and the length of uninsulate tool.
Figure 1: Characteristic of taper on EDM
In the EDM sparking hole drilling process, the viscous resistance in the narrow discharge gap causes difficulty in the removal of debris and bubbles from the working area, abnormal discharges are occurred and resulting in extensive electrode wear (Yu et al. 2009). Moreover, the debris moved by pressure flow of dielectric fluid make taper on the workpiece. The hole taper of workpiece from EDM process, which as shows in Figure 1, can be calculated by equation (1).
Iopcr = tan -1 -d 2L (1)
Where D is hole entrances, d is hole exits, and L is hole length.
This research focuses on influence of machining variables affecting material removal rate (MRR), electrode wear rate (EWR), and taper on martensitic stainless steel AISI 431. 2 ExperimentalProcedure The experiments were carried out on 35 mm of hole depth of martensitic stainless steel AISI 431with ZNC-EDM model JM325DZ manufactured by Joemars company, as shown in Figure2(a). The EDM was carried out on meso-scale machining with a brass tube electrode as *Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189. E-mai l addr esses: mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 473
outside diameter of 1 mm, inner hole diameter of 0.3 mm for flushing by dielectric fluid to remove wear debris and heat ventilation size as shown in Figure 2(b). Principle of tube electrode drilling is shown in Figure 2(c). The experiments were carried out in the de-ionised, because of the advantage of material removal rate (Diver et al. 2004). The chemical compositions and essential physical properties are shown in Table 1 and Table 2, respectively. Table 3 shows the physical properties of an electrode. The experiment conditions are contained in Table 4.
(a) EDM super drill model JM325DZ (b) Brass (Cu-Zn40) tube electrode
(c) ZNC-EDM drilling process
Figure 2: Experimental EDM .
474 Pichai Janmanee, and Apiwat Muttamara
Table 1: Chemical compositions of stainless steel AISI 431. Element C Si Mn Cr Ni S P Weight (%) 0.17 0.6 1.0 17.0 2.0 0.03 0.04
Table 2: Essential physical properties of stainless steel AISI 431. Properties Value Condition Temp. ( o C) Density(x1000 Kg/m 3 ) 7.8 25 Elastic modulus(GPa) 200 25 Tensile strength (MPa) 965 - Thermal conductivity(W/m K) 20.2 100 Electrical resistivity(10 -9 m ) 720 25
Table 3: Physical properties of brass tube electrode. Properties Cu-Zn (60-40) Melting point ( o C) 910 Density (g/cm 3 ) 10.98 g / cm 3
Electrical conductivity(I.A.C.S% at 20 o C) 78~85 Hardness(HRB) 93 Elastic modulus (GPa) 648
Table 4: Experimental conditions. Parameters Values Polarity (Electrode) + Current (A) 1-9 On-time (s) 10,30,50,90 Duty factor (%) 10-90 Servo rate (mm/sec) 2-10 Water pressure (Kg/cm 2 ) 20-60 Spindle speed (rpm) 100 Dielectric fluid De-ionised water 3 ResultsandDiscussion As for the experiments were conducted under five process factors such as ; electrical current, on-time, duty factor, water pressure and servo rate, the data were analyzed as follows: *Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189. E-mai l addr esses: mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 475
3.1 AnalysisofWaterPressure The experiments were conducted by varying the water pressure 20, 30, 40, 60 kg/cm 2 and fixing parameter of current at 9 A, on-time at 10 s, duty factor at 75 %, and servo rate at 2 mm/ sec.
High water pressure has influence to cutting process makes gain of the drilling speed. It increases electrode wearing ratio but reduces taper of drilling wall as shown in Figure3(a-c). Because high water pressure make debris dispose out from clearance space between a workpiece and electrode surfaces. Consequently, complete spark often occurred and thus the material removal rate increased (Diver et al. 2004).
(a) Effect of water pressure to MRR (b) Effect of water pressure to EWR
(c) Effect of water pressure to taper
Figure 3: Variations of water pressure with meso-hole results.
3.2 Analysisofcurrent In this experiment, we consider of each parameter by varying current 1, 2, 3, 5, 7, 9A and fixing of parameter of on-time at 10s, duty factor at 75%, servo rate at 2 mm/sec, and water pressure at 40kg/cm 2 .
As the results in Figure 4(a), it indicates that the increase of material removal rate resulted from the raise in current. High current increases material removal rate ratio and electrode wear ratio as shown in Figure 4(b) (Han et al. 2004). From Figure 4(c), 476 Pichai Janmanee, and Apiwat Muttamara
taper of drilled hole is increased because the discharges produce thermal energy according to an electrical current (Fukuzawa et al. 2004). As estimation of the current increasing while the cross section is still constant, it makes gain of the density of current per cross section area (Sen and Shan, 2005), (Guitrau,1997).
(a) Effect of current to MRR (b)Effect of current to EWR
(c) Effect of current to taper
Figure 4: Variations of current with meso-hole results.
3.3 Analysisofservorate In this experiment, we consider factor of servo rate 2, 4, 6, 8, 10 mm/sec and fix parameter of current 9 A, on-time at 10 s, duty factor at 75 %, and water pressure at 40 kg/cm 2 .
As shown in Figure 5(a), it was found that the increasing of servo rate lead to decreasing of MRR because the spark requires an appropriate gap. If servo rate is set up over the required value, narrow gap will be occurred thus the spark is incomplete or short circuit (Choi and Kim, 1998), (Han et al. 2004). When servo rate increases, electrode wear and taper increases as shown in Figure 5(b-c). It can be explained that EDM sparking on servo rate in the narrow discharge gap changes the contact angle of holes wall and the edge of electrode, observed in Figure 5(c). *Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189. E-mai l addr esses: mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 477
Figure 5(d) shows the phenomena of EDM drilling on shallow and deep holes (Yu et al. 2009). 3.4 AnalysisofDutyFactorandOnTime The duty factor, which means the ratio between pulse duration and pulse cycle time exerts an important role on the performance of EDM as shown in Figure6 (a). In this experiment, we consideration of each parameters by varying duty factor 10, 15, 20, 35, 45, 60, 75, 90 %, on time 10, 30, 50, 90 s, and fixing parameters of current at 9 A, servo rate at 2 mm/sec, and water pressure at 40 kg/cm 2 , respectively.
As can be seen in Figure6 (b-c), the results were found that the each on-time was suitable for only a specific duty factor. MRR increases with increasing of duty factor of each on-time. However, increasing of duty factor leads to decreasing of EWR and taper. Moreover, if increasing of on-time less than 30 s, it still affects to MRR increases. At 75 % of duty factor for on-time 30 and 50 s, they give same values of MRR. However, these parameters results in low EWR and taper.
(a) Effect of servo rate with MRR (b) Effect of servo rate with EWR
(c) Effect of servo rate with taper (d) Edge wear influence to high servo rate
Figure 5: Variations of servo rate with meso-hole results. 478 Pichai Janmanee, and Apiwat Muttamara
(a) Relations of duty factor and cycle time (b) Effect of duty factor to MRR
(c) Effect of duty factor to EWR
(d) Effect of duty factor to taper
Figure 6: Variations of duty factor with meso-hole results.
*Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189. E-mai l addr esses: mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 479
Figure 7 shows impressions of the result from the experiment test with current at 9A, on-time at 10s, duty factor at 75%, servo rate at 2 mm/sec, and water pressure at 40 kg/cm 2 , respectively. It shows the feature of taper could be achieved. Diameter at electrode entry was between 1.08 mm and 0.97 mm as shown in Figure 7(a). Figure 7(b) shows result meso-hole machined exit. Figure 8 shows an image of a section meso-hole machined using the same condition.
(a) Hole entrance (b) Hole exit
Figure 7: Characteristic of meso-hole and electrode results.
Figure 8: SEM image of section meso-hole. 4 Conclusion As the results of the material removal rate, electrode wear, taper in the drill hole meso-scale by brass tube electrode, it can conclude that: 1. The MRR is lower when increasing of servo rate. 2. The taper of hole increases with increasing of electrical current and servo rate. 480 Pichai Janmanee, and Apiwat Muttamara
However, it is reverse proportion to water pressure and duty factor. 5 Acknowledgement This work was supported by the National Research University Project of Thailand Office of Higher Education Commission and the National Research Council of Thailand (NRCT). 6 References Ali S., Hinduja S., Atkinson J., Pandya M. (2009). Shaped tube electrochemical drilling of good quality holes. CIRP Annals - Manufacturing Technology , 58, 185-188. Bilgi D.S., Jain V.K., Shekhar R., Kulkarni A. (2007). Hole quality and inter-electrode gap dynamics during pulse current electrochemical deep hole drilling. International Journal of Advanced Manufacturing Technology, 34, 79-95. Choi I-H.,Kim J-D. (1998). A study of the characteristics of the electrochemical deburring of a governor-shaft cross hole. Journal of Material Processing Technology, 75, 198-203. Diver C., Atkinson J., Helml H.J., Li L. (2004). Micro-EDM drilling of tapered hole for industrial applications. Journal of Material Processing Technology, 149, 296-303. Fukuzawa Y., Mohri N., Tani T. and Muttamara A. (2004). Electrical discharge machining properties of noble crystals. Journal of Materials Processing Technology, 149(1-3), 393 -397. Guitrau E.B. (1997). The EDM Handbook. Handser Gardner publication Cincinnati, 19-54. Han F., Wachi S., Kunieda M. (2004). Improvement of machining characteristics of micro- EDM using transistor type isopulse generator and servo feed control. Precision Engineering, 28, 378385. Jeong Y. H., Min B. K. (2007). Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. International Journal of Machine Tool and Manufacture , 47, 187-1826. Muttamara A., Fukuzawa Y., Mohri N., and Tani T. (2009). Effect of electrode Materials on EDM of Alumina. Journal of Materials Processing Technology, 209, 2545-2552. Muttamara A., Janmanee P., and Fukuzawa Y.(2010). A Study of MicroEDM on Silicon Nitride Using Electrode Materials. International Transaction Journal of Engineering, Management, & Applied Sciences & Technologies, 1(1), 1-7. Rajasekhar A., Madhusudhan Reddy G., Mohandas T. (2009). V.S.R. Murti. Influence of austenitizing temperature on microstructure and mechanical properties of AISI 431 martensitic stainless steel electron beam welds. Materials and Design, 30, 1612-1624. *Cor r espondi ng aut hor (A. Mut t amar a). Tel / Fax: +66-2-5643001 Ext . 3189. E-mai l addr esses: mapi wat @engr . t u. ac. t h. 2011. Int er nat i onal Tr ansact i on Jour nal of Engi neer i ng, Management , & Appl i ed Sci ences & Technol ogi es. Vol ume 2 No. 4. ISSN 2228-9860. eISSN 1906-9642. Onl i ne Avai l abl e at ht t p: / / TuEngr . com/ V02/ 471-481. pdf 481
Sen M., Shan H.S.(2005). A review of electrochemical macro- to micro-hole drilling processes. International Journal of Machine Tool and Manufacture,45, 137-152. Sharma S., Jain V.K., Shekhar R. (2002). Electrochemical drilling of inconel super alloy with acidified NaCl electrolyte. International Journal of Advanced Manufacturing Technology, 19, 492-500. Yu Z.Y., Zhang Y., Li J., Luan J., Zhao F., Guo D. (2009). High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM. CIRP Annals - Manufacturing Technology, 58, 213-216.
Pichai Janmanee is an Assistant Professor in the Department of Industrial Engineering at Rajamangala University of Technology Krungthep (RMUTK), Bangkok, Thailand. He received a BE in Industrial Engineering from Rajamangala University of Technology and ME in Production Engineering from Kings Mongkut University of Technology North Bangkok(KMUTNB). His areas of research include machining and electrical discharge machining of hard materials.9
Dr.Apiwat Muttamara is an Assistant Professor of Department of Industrial Engineering at Thammasat University. He received his B.Eng. from Kasetsart University and the D.Eng. in Materials Science from Nagaoka University of Technology, Japan. His areas of research include machining and electrical discharge machining of hard materials. Peer Review: This article has been internationally peer-reviewed and accepted for publication according to the guidelines given at the journals website.
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