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Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

Electric discharge machining is relatively a slow process in terms of machining time and material removal rate. The presence of overcut and the hole taper angle caused by the excessive tool wear are other challenges in the electric discharge machining die-sinking process. The areas of focus to solve...

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Autores principales: Rafaqat, Madiha, Mufti, Nadeem Ahmad, Saleem, Muhammad Qaiser, Ahmed, Naveed, Rehman, Ateekh Ur, Ali, Muhammad Asad
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10224080/
https://www.ncbi.nlm.nih.gov/pubmed/37241491
http://dx.doi.org/10.3390/ma16103865
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author Rafaqat, Madiha
Mufti, Nadeem Ahmad
Saleem, Muhammad Qaiser
Ahmed, Naveed
Rehman, Ateekh Ur
Ali, Muhammad Asad
author_facet Rafaqat, Madiha
Mufti, Nadeem Ahmad
Saleem, Muhammad Qaiser
Ahmed, Naveed
Rehman, Ateekh Ur
Ali, Muhammad Asad
author_sort Rafaqat, Madiha
collection PubMed
description Electric discharge machining is relatively a slow process in terms of machining time and material removal rate. The presence of overcut and the hole taper angle caused by the excessive tool wear are other challenges in the electric discharge machining die-sinking process. The areas of focus to solve these challenges in the performance of electric discharge machines include increasing the rate of material removal, decreasing the rate of tool wear, and reducing the rate of hole taper angle and overcut. Triangular cross-sectional through-holes have been produced in D2 steel through die-sinking electric discharge machining (EDM). Conventionally, the electrode with uniform triangular cross-section throughout the electrode length is used to machine triangular holes. In this study, new designs of electrodes (non-conventional designs) are employed by introducing circular relief angles. For material removal rate (MRR), tool wear rate (TWR), overcut, taper angle, and surface roughness of the machined holes, the machining performance of conventional and unconventional electrode designs is compared. A significant improvement in MRR (32.6% increase) has been achieved by using non-conventional electrode designs. Similarly, the hole quality resulted by non-conventional electrodes is way better than hole quality corresponding to conventional electrode designs, especially in terms of overcut and hole taper angle. A reduction of 20.6% in overcut and a reduction of 72.5% in taper angle can be achieved through newly designed electrodes. Finally, one electrode design has been selected (electrode with 20 degree relief angle) as the most appropriate electrode resulting in better EDM performance in terms of MRR, TWR, overcut, taper angle, and surface roughness of triangular holes.
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spelling pubmed-102240802023-05-28 Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining Rafaqat, Madiha Mufti, Nadeem Ahmad Saleem, Muhammad Qaiser Ahmed, Naveed Rehman, Ateekh Ur Ali, Muhammad Asad Materials (Basel) Article Electric discharge machining is relatively a slow process in terms of machining time and material removal rate. The presence of overcut and the hole taper angle caused by the excessive tool wear are other challenges in the electric discharge machining die-sinking process. The areas of focus to solve these challenges in the performance of electric discharge machines include increasing the rate of material removal, decreasing the rate of tool wear, and reducing the rate of hole taper angle and overcut. Triangular cross-sectional through-holes have been produced in D2 steel through die-sinking electric discharge machining (EDM). Conventionally, the electrode with uniform triangular cross-section throughout the electrode length is used to machine triangular holes. In this study, new designs of electrodes (non-conventional designs) are employed by introducing circular relief angles. For material removal rate (MRR), tool wear rate (TWR), overcut, taper angle, and surface roughness of the machined holes, the machining performance of conventional and unconventional electrode designs is compared. A significant improvement in MRR (32.6% increase) has been achieved by using non-conventional electrode designs. Similarly, the hole quality resulted by non-conventional electrodes is way better than hole quality corresponding to conventional electrode designs, especially in terms of overcut and hole taper angle. A reduction of 20.6% in overcut and a reduction of 72.5% in taper angle can be achieved through newly designed electrodes. Finally, one electrode design has been selected (electrode with 20 degree relief angle) as the most appropriate electrode resulting in better EDM performance in terms of MRR, TWR, overcut, taper angle, and surface roughness of triangular holes. MDPI 2023-05-20 /pmc/articles/PMC10224080/ /pubmed/37241491 http://dx.doi.org/10.3390/ma16103865 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Rafaqat, Madiha
Mufti, Nadeem Ahmad
Saleem, Muhammad Qaiser
Ahmed, Naveed
Rehman, Ateekh Ur
Ali, Muhammad Asad
Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title_full Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title_fullStr Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title_full_unstemmed Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title_short Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining
title_sort machining of triangular holes in d2 steel by the use of non-conventional electrodes in die-sinking electric discharge machining
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10224080/
https://www.ncbi.nlm.nih.gov/pubmed/37241491
http://dx.doi.org/10.3390/ma16103865
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