PARAMETRIC OPTIMIZATION IN DIE SINKING EDM OF

INCONEL 825 USING COPPER ELECTRODE

1) INTRODUCTION

Electrical discharge machining (EDM), also known as spark machining, spark

eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process
whereby a desired shape is obtained by using electrical discharges (sparks).Die-sinking electric
discharge machining (EDM) is one of the essential non-contact machining processes which is
often used to produce complex profiles. However, machining of super alloys is found to be
difficult even using EDM due to the inadequate process parameter sets affected by improper
parametric correlation. Therefore, this work demonstrates the parametric optimization of EDM
for desired responses.

In the die -sinking electric discharge machining (EDM) process, both electrode and
workpiece are submerged in a dielectric liquid and are connected to a source of current which
is switched on and off automatically depending on the parameters set on the controller. When
the current is switched on, the discharge takes place between points of the anode and the
cathode, the intense heat generated near the zone melts and evaporates the materials in the
sparking zone. It has been observed that if both the electrodes are made of same material, the
electrode connected to the positive terminal generally erodes a faster rate. A suitable gap,
known as spark gap, is maintained between the between the tool and the workpiece surfaces.
The sparks are made to discharge at a high frequency with a suitable source. For maintaining
the predetermined spark gap, a servo unit is generally used. The gap is sensed through the
average voltage across it and this voltage is compared with pre-set value. The difference is used
to control the servomotor. Due to surface irregularities, the gap varies and at instant, it is
minimum at one point. When a suitable voltage is built up across the tool and the workpiece,
an electrostatic field of sufficient strength is established, causing cold emission of electrons
from cathode, accelerates towards anode. After gaining a sufficient velocity the electrons
collide with the molecules of the dielectric fluid, breaking them into electrons and positive
ions. The electrons so produced also accelerate and may ultimately dislodged the other
electrons from the dielectric fluid molecules. Ultimately, a narrow column of ionised dielectric
fluid molecules is established and connect two electrodes. As a result of this spark, a
compression shock wave is generated and a very high temperature is developed on the
electrodes (10,000-12,000’c). This temperature causes the melting and vaporisation of
electrode materials, and molten metals are evacuated by a mechanical blast, resulting in small
centres on both the electrodes. As soon as this happens, the gap between the electrodes
increases and it moves to next shortest gap for the spark.Material removal rate from the cathode
is comparatively less than that from anode due to momentum with which the stream of electrons
strikes the anode is much more than that due to the stream of positive ions impinging on the
cathodes though the mass of an individual electron is less than that of positive ions.
Some advantages of EDM are that hardness, toughness or brittleness of the material
poses no problems. Due to this EDM can be used for machining materials that are too hard or
brittle to be machined by conventional methods. The method does not leave any chips or burrs
on the work piece. Cutting forces are virtually zero, so very delicate and fine work can be done.
The main disadvantage of die sink EDM is only electrically conductive materials can be
machined by EDM. Thus non - metallic, such as plastics, ceramics or glass, cannot be machined
by EDM and MRR is quite low.

With the development of technology, many new materials and alloys that have been developed
for specific uses possess a very low machinability. Producing complicated geometries in such
materials becomes very difficult with the usual methods i.e. with lathe or milling. Also,
sometimes the combination of the material properties and the job dimensions is such that the
use of the traditional processes become impossible. Example of such types of job is the
machining of a complicated turbine blade made of super alloys and machining of materials
such as tungsten carbide, Inconel which are too hard. For the purpose of machining such type
of material or super alloy which are too hard and difficult to machine by traditional machining
process, Electrical Discharge Machine is used. Also EDM has other advantages over traditional
machining as cutting complex shape and thin walled configuration without any distortion.

2) LITERATURE SURVEY
1. Brijesh Gupta and S.C. Jayswal have investigated the parametric optimisation of tool
wear rate using taguchi method taking DIN1.2714 as workpiece and Square copper as
electrode with kerosene as dielectric fluid. The varying parameters are discharge
current , pulse on time ,pulse off time, voltage. The chemical composition of
DIN1.2714 is 0.59% carbon,0.83% manganese,0.28% silicon,1.13%
 chromium,0.013% phosphorous,1.58% nickel,0.46% molybdenum,0.71% vanadium.
The hardening temperature is 850 degree celsius to 900 degree Celsius. It has high
strength, high hardness , high wear resistance. Applications of DIN1.2714 is in
extrusion die,hot forging tool, dies for processing tin, lead, zinc alloys. The results
shows that discharge current is main parameter that influence TWR. The % contribution
of current is 71.69% , pulse on time is 25.28%, pulse off time is 1.19%, flushing
pressure is 1.12% and voltage is 0.008%. The optimal parameters are 15A, 70V, pulse
on time 150microseconds , pulse off time 90 microseconds,dielectric pressure
0.25kg/cm^2 to obtain maximum TWR.

2. P. Balasubramanium and T. Senthilvelan have discussed the optimisation of machining

parameters using cast & sintered copper electrode. The Response Surface Methodology
is used with EN8 and D3 steel as workpiece . EN8 steel has high wear resistance ,good
homogenous metallurgical structure , consistent machining properties. Application are
shafts, gears, spindles, bolts&studs . D3 steel is high carbon ,high chromium tool steel
having excellent wear resistance , good dimensional stability& high compressive
strength. Application are blanking & forming dies , press tools, punches. Effects of peak
current, pulse on time, die electric pressure, tool diameter on material removal
rate(MRR), tool wear rate (TWR), surface roughness(SR) is studied. Scanned electron
microscope (SEM) images of both electrodes after machining is taken to study structure
property correlation. The results obtained are as follow;

EN8 and cast copper electrode- With increase in peak current, dielectric pressure the MRR
increases, increase in peak current and tool diameter increases TWR. Keeping pulse off
time low, dielectric pressure high SR is minimised but on increasing pulse on time SR
increases.EN8 and sintered copper electrode – With the increase in current, tool diameter
there is increase in MRR, at low pulse on time and high tool diameter TWR increased. If
peak current and pulse on time is low then SR is minimum.D3 and cast copper electrode-
On increasing current and tool diameter MRR increases, at low peak current and pulse on
time the TWR increases while SR decreases.D3 and sintered copper electrode- With
increase in current and tool diameter MRR increases, at low pulse on time and high tool
diameter TWR increases and increasing peak current & pressure keeping pulse on time &
diameter at middle level ,SR is minimum.
3. The research work of Soni & chakraverti (1994) introduced rotary disc for grooving
operation on titanium alloy. The rotary electrode was placed above the work material.
The improvement in MRR due to better flushing action & sparking efficiency with little
TWR but the surface finish was improved.

4. Ghoreishi & Atkinson (2002) compared the effects of high & low frequency forced
axial vibration of the electrode , rotation of electrode & combination of both ( vibro-
rotary) in respect of MRR, TWR & SQ. The results shows that vibro rotary increases
MRR by up to 35% compared with vibration EDM and by upto 100% compared with
rotary EDM in semi finishing.
5. F. Klocke and M. Schwade machined five different grades of graphite to optimise MRR
and TWR by using the different properties of each grade. Following observations were
made with each grade of different specific electrical conductance, thermal conductivity
and grain size:MRR increases with increase in thermal conductivity due to more heat
energy on workpiece, Grain size has no direct influence on TWR and MRR, MRR
increases with increase in electrical resistance, Thermal conductivity has no direct
influence on TWR.

6. Kamal Pal and Manisha Priyadarshini did Grey Taguchi based optimization of EDM
processes for titanium alloy using L25 orthogonal method.
Dielectrics used were paraffin oil and EDM 30 in the ratio 1:1.
Following observations were made:
Influence on MRR: Increase in pulse current produces stronger spark which produces
the higher temperature and causes more material to melt and erode from workpiece.
Influence on TWR: Pulse-on time (40.27%) has max. contribution followed by peak
current (38.14%), duty factor (13.13%) ha less impact whereas gap volt. has minimum
impact. Influence on Surface Roughness: Peak current (46.54%) has max contribution
followed by pulse on time (41.35%) with gap voltage (4.1%) and duty factor (1.8%)
has low impact. They concluded that best optimised value for maximum MRR, lowest
TWR and Surface Roughness are as follows:

Peak current:10A Pulse-ON time:10us

Duty factor:9 Gap Voltage:8V
7. Chinmaya P. Mohanty, Siba Sankar Mahapatra Manas Ranjan Singh uses Inconel 718
and electrode materials are Graphite, Brass and Copper and chooses the process
parameters open circuit voltage(OCV), discharge current(IP), Pulse on time(TON), duty
factor, flushing pressure and electrode material and measured characteristics are metal
removal rate(MRR), tool wear rate(TWR), surface roughness(SR). Taguchi’s L27
orthogonal, QPSO, PSO and non-linear regression analysis has been used and found
that:
MRR increases with decrease in open circuit voltage from 90V to 70V, Increase in
discharge current from 3A to 7A, Increase in duty factor,
MRR(Graphite)>MRR(Copper)>MRR(Brass).

TWR increases with Increase in discharge current, Decrease in pulse on time,

TWR(Brass)>TWR(Copper)>TWR(Graphite)

SR increases with Increase in discharge current, Increase in pulse on time, Increase with
open circuit voltage, SR(Graphite)>SR(Copper)>SR(Brass)

8. A. Dey, S. Debnath, K. M. Pandey used Al6061/cenoshere composites as a workpiece

using a hybrid approach of grey based RSM and circular copper electrode of 10mm in
diameter. The dielectric fluid was commercial grade hydrocarbon oil and impulse jet
flushing was utilized. Parameters are Ip, Ton, Volume fraction of reinforcement,
Flushing pressure and measured characteristics are MRR, TWR, SR and the optimal
level of process parameters was identified as pulse current of 9.9126A, pulse on time
of 210.002us, reinforcement content 3.6936% and flushing pressure of 0.5999 MPa.
9. Chen Sl did investigation on the influence of kerosene and distilled water as dielectric
onTi-6Al-4V workpieces. He found that carbide is formed on the workpiece surface
while using kerosene whereas oxide is formed on the workpiece surface while using
distilled water. The debris size of Ti-6Al-4V alloy in distilled water is greater than that
in kerosene and compared to kerosene, the impulsive force of the discharge in distilled
water is smaller but more stable.

10. Abdul kareem worked with titanium alloy(Ti-6Al-4V) using cryogenically cooled tool
electrode. During cryogenic treatment, the part component is immersed into liquid
nitrogen. And temp. is reduced to -1840C at a cooling rate of 1oC/min and kept container
for 24 hr. then the temp. is gradually raised to room temp. He conclude that there
 was 27% reduction in electrode wear and surface finish was better due to cryogenically
tool electrode.
11. Safian sharif took stainless steel 316L as workpiece and copper impregnated graphite
as tool electrode. The process parameter taken by him was peak current, pulse ON time,
pulse OFF time and servo voltage and performance parameter was Material removal
rate(MRR), tool wear rate(TWR), Surface roughness(SR) and Dimensional accuracy
(DA). By using ANOVA and central composite design (CCD) method, he given a
relation which shows that all the process parameter except servo voltage was considered
as significant factor for performance parameter.

3) METHODOLOGY
TOOL AND WORKPIECE MATERIAL

Inconel 825

Inconel 825 alloys is a nickel chromium based alloy with the addition of iron, molybdenum,
titanium and copper. Inconel 825 has excellent mechanical and chemical properties at elevated
temperatures, highly corrosion resistant in reducing and oxidizing atmosphere, resistance to
chloride pitting and very stable austenitic structures.

Applications of Inconel 825: Sulphuric acid piping and vessels, Phosphoric acid evaporators,
Propellor shaft, Calorifiers, Aerospace, Pickling tank heaters, pickling tanks and equipments,
Chemical process equipment, Electrostatic precipitator electrodes, Marine exhaust system,
Pressure vessels.

Copper

Copper electrodes has been used as electrode because it is easily available, cheap and decent
MRR (in between Graphite and Brass), TWR (in between Graphite and Brass), SR (in between
Graphite and Brass).

Dielectric fluid

A dielectric fluid is a medium that does not conduct electricity. In EDM process, the function
of dielectric are:

i. It acts as an insulating medium.

ii. It cools the spark region and helps in keeping the tool and workpiece cool.
 iii. It maintains a constant resistance across the gap.
iv. It carries away the eroded metal particles.
v. A dielectric must have following properties:
vi. It should have low viscosity and good wetting capacity.
vii. It should be chemically neutral.
viii. It should not evolve toxic fumes during entire process.
ix. It should have high flash point.
x. It should be less costly and easily available.

The various mediums which are used as dielectric are : petroleum based oil, paraffin, white
spirit, transformer oil, kerosene, mineral oil, distilled water or combination of distilled water
with ethylene glycol etc.

Out of those, we use EDM Oil as dielectric medium for our experiment.

PARAMETERS OF EDM

Process parameters-These are used to control the performance measures of the machining
process.

Pulse on time -It is the duration of time expressed in micro seconds in whom the peak current
is ready to flow in every cycle. This is the time in which energy removes the metallic particles
from the work piece. This energy is controlled by the peak current and the length of the on-
time. With the increase in pulse on time, MRR increases because discharge energy increases
with pulse on time and peak current leading to faster cutting rate and TWR decreases and SR
increases

Pulse off-time- It is the period of time expressed in micro seconds between the two pulses on
time. This time permits the melted particle to coagulate on to the work piece and to be wash
away by flushing method of the arc gap. As pulse off time decreases, the MRR increases
because the no. of discharges within the given period becomes more which leads to higher
cutting rate and TWR decreases and SR increases

Arc gap- It is gap between the electrode and work piece in which the spark generate for eroding
the metal from the work piece. It is very thin gap in the range of 10 – 125 μm.

Discharge current- Current is measured in ampere (A). Discharge current is responsible

directly for material removal. It contains energy for melting and evaporation. When current
increases, the MRR also increases. The higher the current, intensity of spark is increased and
results in high metal removal will takes place, TWR and SR also increases

Duty cycle- It is a percentage of the on-time relative to the total cycle time. This parameter is
calculated by dividing the on-time by the total cycle time. MRR increases with increase in duty
factor.

Voltage- It is the potential applied between the tool and workpiece and affects the material
removal rate. With the increase in working voltage, MRR increases, TWR decreases and SR
decreases.

Performance parameters-These parameters measures the various process performances of

EDM results.

Material removal rate(MRR): MRR is a performance measure for the erosion rate of the
workpiece and is typically used to quantify the speed at which machining is carried out. It is
expressed as the volumetric amount of workpiece material removed per unit time.

Tool wear rate (TWR): TWR is a performance measure for the erosion rate of the tool electrode
and is a factor commonly taken into account when considering the geometrical accuracy of the
machined feature. It is expressed as the volumetric amount of tool electrode material removed
per unit time.

Surface Quality(SQ): Surface quality is a broad performance measure used to describe the
condition of the machined surface. It comprises components such as surface roughness (SR),
extent of heat affected zone (HAZ), recast layer thickness and micro-crack density. The White
Layer or Recast Layer (WL/RCL) is the layer which is formed by the unexpelled molten metal
being rapidly cooled by the dielectric fluid during the flushing process. The Heat-Affected
Zone (HAZ) is the layer which lies below the recast layer. This is formed due to altering the
metallurgical properties of the metal.
4) REFERENCES:

 Pal Kamal, Priyadarshini Manisha, Grey Taguchi based optimization of EDM processes
for titanium alloy, 2015
 F. Klocke, M.Schwade, Analysis of MRR and electrode wear in sinking edm roughing
strategies using different graphite grades, 2016.
 Balasubramanium p., Senthilvelan t., 2014. “Optimization of Machining Parameters in
EDM process using Cast and Sintered Copper Electrodes”. Procedia Material science
6(2014) 1292-1302.
 Gupta Brijesh,Jayswal S.C.,2015. “Parametric Optimization of TWR On Die Sinking
EDM By Using Taguchi’s Approch”.Internatinal Journal Of Mechanical and
Production Engineering 2320-2092, Vol 3 ,Issue 10.
 Sarif Safian, Safie Wahaizad “Experiment study of EDM on stainless steel 316L using
design of experiment”
 Rahul,Datta Saurav, “Electrical discharge machining of INCONEL 825 using
cryogenically treated copper electrode”
 Chakraborty S., dey v. and ghosh s.k. “A review on the use of dielectric fluid and their
effect in edm characteristics”
 Dey A. Debnath S., Pandey K. M. “optimisation of electrical discharge machining
process for Al6061/cenosphere using grey based hybrid approach”.
 Mohanty Chinmaya P., Sankar Siba “ optimise the edm process parameter using utility
concept and QPSO algorithm”.