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Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy

Year 2022, Volume: 3 Issue: 1, 47 - 58, 29.04.2022
https://doi.org/10.52795/mateca.1087726

Abstract

Aluminum alloys are widely preferred in various fields such as aerospace, ship and automotive due to their lightness and relevant production cost. In this study, electro discharge technique was used in the processing of aluminum 5083 alloy (Al5083) produced by powder metallurgy method. The surface quality resulting from the experiments was investigated in terms of Ra, Rz and Rsm. Experimental studies were carried out according to Taguchi L9 orthogonal experimental design, using three different levels of discharge current, pulse on time and pulse off time parameters. As the discharge current increased, Ra and Rz increased, Rsm first decreased and then increased. As the pulse on time increased, Ra and Rz first increased and then decreased, and Rsm increased. When the pulse off time increased, Ra and Rz decreased and Rsm increased. As a result of the analysis of variance (ANOVA) performed to determine the effect rates of the variable parameters on the surface quality, the order of importance of the parameters was found to be discharge current, pulse off time and pulse on time. The effect of discharge current, which is the most effective parameter according to ANOVA, on Ra, Rz and Rsm was calculated as respectively 70.87%, 70.41% and 36.34%. Microscopic images taken from the tool (copper) and workpiece surface show that the craters and peaks formed by the spark effect are formed on both material surfaces.

References

  • 1. TMMOB Metalurji Mühendisleri Odası, Alüminyum raporu, Metalurji, (137): 1–43, 2004.
  • 2. G. Önal, A. Ünüvar, T. Şi̇mşek, 5083 Al-Mg alaşımında mekanik özellikler üzerine korozyon etkisinin araştırılması, Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 20 (2): 191–196, 2013.
  • 3. A. Kaya, M. Aslan, N. F. Yilmaz, H. Kurt, Al-Mg-SiC kompozitlerin görünür yoğunluklarının Taguchi analizi, El-Cezeri, 7 (2): 773–780, 2020.
  • 4. M. C. Santos, A. R. Machado, W. F. Sales, M. A. S. Barrozo, E. O. Ezugwu, Machining of aluminum alloys: a review, The International Journal of Advanced Manufacturing Technology, 86 (9): 3067–3080, 2016.
  • 5. Y. Sun, L. Jin, Y. Gong, X. Wen, G. Yin, Q. Wen, B. Tang, Experimental evaluation of surface generation and force time-varying characteristics of curvilinear grooved micro end mills fabricated by EDM, Journal of Manufacturing Processes, 73: 799–814, 2022.
  • 6. M. P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, John Wiley & Sons, 4. Ed., 2010.
  • 7. N. M. Kumar, S. S. Kumaran, L. A. Kumaraswamidhas, An investigation of mechanical properties and material removal rate, tool wear rate in EDM machining process of AL2618 alloy reinforced with Si3N4, AlN and ZrB2 composites, Journal of Alloys and Compounds, 650: 318–327, 2015.
  • 8. L. Selvarajan, R. Sasikumar, N. Senthil Kumar, P. Kolochi, P. Naveen Kumar, Effect of EDM parameters on material removal rate, tool wear rate and geometrical errors of aluminium material, Materials Today: Proceedings, 46: 9392–9396, 2021.
  • 9. O. Poyrazoğlu, Elektriksel kıvılcımla aşındırma metodu ile işleme edm elektroerozyon tekni̇ği̇, TEKEV, Ankara, 1994.
  • 10. P. N. Singh, K. Raghukandan, B. C. Pai, Optimization by Grey relational analysis of EDM parameters on machining Al–10%SiCP composites, Journal of Materials Processing Technology, 155–156: 1658–1661, 2004.
  • 11. C. R. Sanghani, G. D. Acharya, A review of research on improvement and optimization of performance measures for electrical discharge machining, Journal of Engineering Research And Applications, 4 (1): 433–450, 2014.
  • 12. W. König, Fertigungsverfahren 3: Abtragen, Generieren und Lasermaterialbearbeitung, 4. Ed., Springer-Verlag, Berlin Heidelberg, (2007).
  • 13. I. Ayesta, O. Flaño, B. Izquierdo, J. A. Sanchez, S. Plaza, Experimental study on debris evacuation during slot EDMing, Procedia CIRP, 42: 6–11, 2016.
  • 14. T. Koyano, S. Suzuki, A. Hosokawa, T. Furumoto, Study on the effect of external hydrostatic pressure on electrical discharge machining, Procedia CIRP, 42: 46–50, 2016.
  • 15. A. Kalyon, Alüminyum 6082 alaşımının pirinç elektrot ile işlenebilirliğinin optimizasyonu, El-Cezeri, 6 (1): 118–130, 2019.
  • 16. W. Safiei, M. R. R. M. Amin, Experimental investigation of EDM die sinking process parameters on Aluminium alloy 5083 using design of experiment, International Journal of Engineering Technology and Sciences, 4 (1): 138–144, 2017.
  • 17. Y. H. Guu, M. T.-K. Hou, Effect of machining parameters on surface textures in EDM of Fe-Mn-Al alloy, Materials Science and Engineering: A, 466 (1): 61–67, 2007.
  • 18. R. Cakiroglu, M. Günay, Elektro erozyonla tornalama yöntemiyle işlenen soğuk iş takım çeliğinin yorulma ömrünün tahmini, Politeknik Dergisi, 24 (2): 495–502, 2021.
  • 19. S. H. Lee, X. Li, Study of the surface integrity of the machined workpiece in the EDM of tungsten carbide, Journal of Materials Processing Technology, 139 (1): 315–321, 2003.
  • 20. E. Pujiyulianto, Suyitno, Effect of pulse current in manufacturing of cardiovascular stent using EDM die-sinking, The International Journal of Advanced Manufacturing Technology, 112 (11): 3031–3039, 2021.
  • 21. H. Ramasawmy, L. Blunt, Effect of EDM process parameters on 3D surface topography, Journal of Materials Processing Technology, 148 (2): 155–164, 2004.
  • 22. H. T. Lee, T. Y. Tai, Relationship between EDM parameters and surface crack formation, Journal of Materials Processing Technology, 142 (3): 676–683, 2003.
  • 23. A. A. Khan, M. Y. Ali, M. M. Haque, A study of electrode shape configuration on the performance of die sinking EDM, International Journal of Mechanical and Materials Engineering, 4 (1): 19–23, 2009.
  • 24. F. Yerui, G. Yongfeng, L. Zongfeng, Experimental Investigation of EDM Parameters for TiC/Ni Cermet Machining, Procedia CIRP, 42: 18–22, 2016.
  • 25. M. Günay, E. Yücel, Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron, Measurement, 46 (2): 913–919, 2013.
  • 26. Y. H. Guu, K.-L. Tsai, L.-K. Chen, An experimental study on electrical discharge machining of Manganese–Zinc ferrite magnetic material, Materials and Manufacturing Processes, 22 (1): 66–70, 2007.
  • 27. V. Prakash, Shubham, P. Kumar, P. K. Singh, A. K. Das, S. Chattopadhyaya, A. Mandal, A. R. Dixit, Surface alloying of miniature components by micro-electrical discharge process, Materials and Manufacturing Processes, 33 (10): 1051–1061, 2018.
  • 28. R. Davis, A. Singh, S. Kachhap, Experimental investigation of the effect of input control variables in near dry electric discharge drilling process, Materials Today: Proceedings, 18: 3027–3033, 2019.
  • 29. J. E. A. Qudeiri, A. Zaiout, A.-H. I. Mourad, M. H. Abidi, A. Elkaseer, Principles and characteristics of different EDM processes in machining tool and die steels, Applied Sciences, 10 (6): 2082, 2020.
  • 30. A. Equbal, A. K. Sood, Electrical discharge machining: an overview on various areas of research, Manufacturing and Industrial Engineering, 13: 1–6, 2014.
  • 31. N. Mohri, M. Suzuki, M. Furuya, N. Saito, A. Kobayashi, Electrode wear process in electrical discharge machinings, CIRP Annals, 44 (1): 165–168, 1995

Toz Metalürjisi ile Üretilmiş Al 5083 Alaşımının Elektro Erozyon ile İşlenmesinde İş Parçası ve Takım Yüzey Yapısının İncelenmesi

Year 2022, Volume: 3 Issue: 1, 47 - 58, 29.04.2022
https://doi.org/10.52795/mateca.1087726

Abstract

Alüminyum alaşımları hafifliği ve uygun üretim maliyetiyle havacılık, gemi ve otomotiv gibi çeşitli alanlarda yaygın olarak tercih edilmektedir. Bu çalışmada toz metalurji yöntemi ile üretilen alüminyum 5083 alaşımının (Al5083) işlenmesinde elektro erozyon tekniği kullanılmıştır. Yapılan deneyler sonucu oluşan yüzey kalitesi Ra, Rz ve Rsm cinsinden incelenmiştir. Deneysel çalışmalar, üç farklı seviyede boşalım akımı, vurum süresi ve vurum aralığı parametreleri kullanılarak Taguchi L9 ortogonal deney tasarımına göre yapılmıştır. Boşalım akımı arttıkça Ra ve Rz artmış, Rsm önce azalmış sonra artmıştır. Vurum süresi arttıkça Ra ve Rz önce artmış sonra azalmış, Rsm ise artmıştır. Vurum aralığı arttığında ise Ra ve Rz azalırken, Rsm değerleri artmıştır. İşleme parametrelerinin yüzey kalitesi üzerindeki etki oranlarının belirlenmesi amacı ile yapılan varyans analizi (ANOVA) sonucu parametrelerin önem sırası boşalım akımı, vurum aralığı ve vurum süresi şeklinde bulunmuştur. ANOVA’ya göre en etkili parametre olan boşalım akımının Ra, Rz ve Rsm’ye etkisi sırasıyla %70.87, %70.41 ve %36.34 olarak hesaplanmıştır. Takım (bakır) ve iş parçası yüzeyinden alınan mikroskopik görüntüler kıvılcım etkisi ile oluşan krater ve tepelerin her iki malzeme yüzeyinde de oluştuğunu göstermektedir.

References

  • 1. TMMOB Metalurji Mühendisleri Odası, Alüminyum raporu, Metalurji, (137): 1–43, 2004.
  • 2. G. Önal, A. Ünüvar, T. Şi̇mşek, 5083 Al-Mg alaşımında mekanik özellikler üzerine korozyon etkisinin araştırılması, Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 20 (2): 191–196, 2013.
  • 3. A. Kaya, M. Aslan, N. F. Yilmaz, H. Kurt, Al-Mg-SiC kompozitlerin görünür yoğunluklarının Taguchi analizi, El-Cezeri, 7 (2): 773–780, 2020.
  • 4. M. C. Santos, A. R. Machado, W. F. Sales, M. A. S. Barrozo, E. O. Ezugwu, Machining of aluminum alloys: a review, The International Journal of Advanced Manufacturing Technology, 86 (9): 3067–3080, 2016.
  • 5. Y. Sun, L. Jin, Y. Gong, X. Wen, G. Yin, Q. Wen, B. Tang, Experimental evaluation of surface generation and force time-varying characteristics of curvilinear grooved micro end mills fabricated by EDM, Journal of Manufacturing Processes, 73: 799–814, 2022.
  • 6. M. P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, John Wiley & Sons, 4. Ed., 2010.
  • 7. N. M. Kumar, S. S. Kumaran, L. A. Kumaraswamidhas, An investigation of mechanical properties and material removal rate, tool wear rate in EDM machining process of AL2618 alloy reinforced with Si3N4, AlN and ZrB2 composites, Journal of Alloys and Compounds, 650: 318–327, 2015.
  • 8. L. Selvarajan, R. Sasikumar, N. Senthil Kumar, P. Kolochi, P. Naveen Kumar, Effect of EDM parameters on material removal rate, tool wear rate and geometrical errors of aluminium material, Materials Today: Proceedings, 46: 9392–9396, 2021.
  • 9. O. Poyrazoğlu, Elektriksel kıvılcımla aşındırma metodu ile işleme edm elektroerozyon tekni̇ği̇, TEKEV, Ankara, 1994.
  • 10. P. N. Singh, K. Raghukandan, B. C. Pai, Optimization by Grey relational analysis of EDM parameters on machining Al–10%SiCP composites, Journal of Materials Processing Technology, 155–156: 1658–1661, 2004.
  • 11. C. R. Sanghani, G. D. Acharya, A review of research on improvement and optimization of performance measures for electrical discharge machining, Journal of Engineering Research And Applications, 4 (1): 433–450, 2014.
  • 12. W. König, Fertigungsverfahren 3: Abtragen, Generieren und Lasermaterialbearbeitung, 4. Ed., Springer-Verlag, Berlin Heidelberg, (2007).
  • 13. I. Ayesta, O. Flaño, B. Izquierdo, J. A. Sanchez, S. Plaza, Experimental study on debris evacuation during slot EDMing, Procedia CIRP, 42: 6–11, 2016.
  • 14. T. Koyano, S. Suzuki, A. Hosokawa, T. Furumoto, Study on the effect of external hydrostatic pressure on electrical discharge machining, Procedia CIRP, 42: 46–50, 2016.
  • 15. A. Kalyon, Alüminyum 6082 alaşımının pirinç elektrot ile işlenebilirliğinin optimizasyonu, El-Cezeri, 6 (1): 118–130, 2019.
  • 16. W. Safiei, M. R. R. M. Amin, Experimental investigation of EDM die sinking process parameters on Aluminium alloy 5083 using design of experiment, International Journal of Engineering Technology and Sciences, 4 (1): 138–144, 2017.
  • 17. Y. H. Guu, M. T.-K. Hou, Effect of machining parameters on surface textures in EDM of Fe-Mn-Al alloy, Materials Science and Engineering: A, 466 (1): 61–67, 2007.
  • 18. R. Cakiroglu, M. Günay, Elektro erozyonla tornalama yöntemiyle işlenen soğuk iş takım çeliğinin yorulma ömrünün tahmini, Politeknik Dergisi, 24 (2): 495–502, 2021.
  • 19. S. H. Lee, X. Li, Study of the surface integrity of the machined workpiece in the EDM of tungsten carbide, Journal of Materials Processing Technology, 139 (1): 315–321, 2003.
  • 20. E. Pujiyulianto, Suyitno, Effect of pulse current in manufacturing of cardiovascular stent using EDM die-sinking, The International Journal of Advanced Manufacturing Technology, 112 (11): 3031–3039, 2021.
  • 21. H. Ramasawmy, L. Blunt, Effect of EDM process parameters on 3D surface topography, Journal of Materials Processing Technology, 148 (2): 155–164, 2004.
  • 22. H. T. Lee, T. Y. Tai, Relationship between EDM parameters and surface crack formation, Journal of Materials Processing Technology, 142 (3): 676–683, 2003.
  • 23. A. A. Khan, M. Y. Ali, M. M. Haque, A study of electrode shape configuration on the performance of die sinking EDM, International Journal of Mechanical and Materials Engineering, 4 (1): 19–23, 2009.
  • 24. F. Yerui, G. Yongfeng, L. Zongfeng, Experimental Investigation of EDM Parameters for TiC/Ni Cermet Machining, Procedia CIRP, 42: 18–22, 2016.
  • 25. M. Günay, E. Yücel, Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron, Measurement, 46 (2): 913–919, 2013.
  • 26. Y. H. Guu, K.-L. Tsai, L.-K. Chen, An experimental study on electrical discharge machining of Manganese–Zinc ferrite magnetic material, Materials and Manufacturing Processes, 22 (1): 66–70, 2007.
  • 27. V. Prakash, Shubham, P. Kumar, P. K. Singh, A. K. Das, S. Chattopadhyaya, A. Mandal, A. R. Dixit, Surface alloying of miniature components by micro-electrical discharge process, Materials and Manufacturing Processes, 33 (10): 1051–1061, 2018.
  • 28. R. Davis, A. Singh, S. Kachhap, Experimental investigation of the effect of input control variables in near dry electric discharge drilling process, Materials Today: Proceedings, 18: 3027–3033, 2019.
  • 29. J. E. A. Qudeiri, A. Zaiout, A.-H. I. Mourad, M. H. Abidi, A. Elkaseer, Principles and characteristics of different EDM processes in machining tool and die steels, Applied Sciences, 10 (6): 2082, 2020.
  • 30. A. Equbal, A. K. Sood, Electrical discharge machining: an overview on various areas of research, Manufacturing and Industrial Engineering, 13: 1–6, 2014.
  • 31. N. Mohri, M. Suzuki, M. Furuya, N. Saito, A. Kobayashi, Electrode wear process in electrical discharge machinings, CIRP Annals, 44 (1): 165–168, 1995
There are 31 citations in total.

Details

Primary Language English
Subjects Manufacturing and Industrial Engineering
Journal Section Research Articles
Authors

Ahmet Tolunay Işık 0000-0003-1598-1828

Ramazan Cakıroglu 0000-0002-3120-1599

Early Pub Date April 22, 2022
Publication Date April 29, 2022
Submission Date March 14, 2022
Published in Issue Year 2022 Volume: 3 Issue: 1

Cite

APA Işık, A. T., & Cakıroglu, R. (2022). Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy. İmalat Teknolojileri Ve Uygulamaları, 3(1), 47-58. https://doi.org/10.52795/mateca.1087726
AMA Işık AT, Cakıroglu R. Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy. MATECA. April 2022;3(1):47-58. doi:10.52795/mateca.1087726
Chicago Işık, Ahmet Tolunay, and Ramazan Cakıroglu. “Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy”. İmalat Teknolojileri Ve Uygulamaları 3, no. 1 (April 2022): 47-58. https://doi.org/10.52795/mateca.1087726.
EndNote Işık AT, Cakıroglu R (April 1, 2022) Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy. İmalat Teknolojileri ve Uygulamaları 3 1 47–58.
IEEE A. T. Işık and R. Cakıroglu, “Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy”, MATECA, vol. 3, no. 1, pp. 47–58, 2022, doi: 10.52795/mateca.1087726.
ISNAD Işık, Ahmet Tolunay - Cakıroglu, Ramazan. “Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy”. İmalat Teknolojileri ve Uygulamaları 3/1 (April 2022), 47-58. https://doi.org/10.52795/mateca.1087726.
JAMA Işık AT, Cakıroglu R. Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy. MATECA. 2022;3:47–58.
MLA Işık, Ahmet Tolunay and Ramazan Cakıroglu. “Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy”. İmalat Teknolojileri Ve Uygulamaları, vol. 3, no. 1, 2022, pp. 47-58, doi:10.52795/mateca.1087726.
Vancouver Işık AT, Cakıroglu R. Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy. MATECA. 2022;3(1):47-58.