DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

STUDY THE EFFECT OF PROCESS PARAMETERS ON POWDER-

MIXED ELECTRICAL DISCHARGE MACHINING OF TUNGSTEN
CARBIDE
Jagdeep Singh1, *, Rajiv Kumar Sharma1,
1
Mechanical Engineering Department
National Institute of Technology Hamirpur-177005, INDIA. Corresponding author:
erjagdeep88@gmail.com, Tel: +91-8629800908

ABSTRACT
This work shows the effect of graphite and alumina powder-mixed electrical discharge
machining of tungsten carbide (WC) using Taguchi approach. The Taguchi method helps to
minimize the number of performed experiments by providing appropriate orthogonal array. In
this work, L27 orthogonal array is used to investigate the machining characteristics, and to
predict the optimal choice for each EDM parameter such as pulse-on time, pulse-off time,
current and powder. It is found that these parameters have a significant influence on
machining characteristic such as surface roughness (SR) and micro-hardness (M-H). The
signal-to-noise ratio for the response characteristics has also been calculated to perform detail
investigation. Response tables (mean and S/N ratio) are used to optimize the process
parameters. Further, analysis of variance (ANOVA) has been performed to show the
significance and percentage contribution of each factor into the study. Powders are found
useful to improve the process mechanism. Both the response characteristics are contradictory
in nature, needs detailed investigation.
NOMENCLATURE
PM-EDM: Powder-mixed electrical discharge machining
M-H: Micro-hardness
SR: Surface roghness
C: Carbon
Al2O3: Alumina

1. INTRODUCTION
Electrical discharge machining (EDM) has ability to machine the high strength temperature
resistant (HSTR) alloys and difficult-to-machine (DTM) materials having very complex and
sophisticated shapes. The process is most widely used in mould and die making industry and
in manufacturing automotive, aerospace and surgical components. In mechanism of EDM,
unwanted parts of workpiece is removed by the high temperature spark and many defects
such as cracks, porosity, residual stress, improper recast layer are easily found on the
machined surface due to very rapid high temperature melting and cooling during EDM
process [1]. Therefore in spite of remarkable process capabilities, its low machining
efficiency and poor surface finish restricted its further applications [2]. Hence an innovative
technique known as powder mixed EDM has been performed in the presence of foreign
particles suspended in dielectric medium to overcome some of the limitations of conventional
EDM [3, 4] which has gained special attention in improving process capabilities,
characteristics and stability of process [5-7].

2. BACKGROUND AND REVIEW

In literature studies, Jahan et al. [7], Sharma and Singh [8] carried out a detailed review on
current research developments in additives/ powders mixed EDM of DTM materials and
concluded that it is still at developing and emerging technique. Thus, fundamental issues

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

related with process variables require further investigation. Lin et al. [9], Kanagarajan et al.
[10],Lee and Li [11], Amorim et al. [12] analyzed the effect of various EDM parameters on
the characteristics of WC, but till no author performed powder-mixed EDM of WC. In
literature, only one author called Kung et al. [13] investigate the PM-EDM of WC-Co by
using Al as additives and studied the optimal machining parameters for process by using
RSM. MahdavinejadandMahdavinejad [14]investigated the instability of EDM process
during machining WCCo composite of different compositions. AssarzadehandGhoreishi
[15] optimized process parameters in EDM of WC by response surface methodology and
analyzed the results of material removal rate (MRR), tool wear rate (TWR) and surface
roughness (SR), found that during EDM of WC, smooth surfaces are obtainable at low
currents and pulse-on times.Pecas and Henrique [16] analyzed the presence of powder
particles in dielectric fluid and stated that the concentration of powder creates conditions
suitable for achieving better surface quality in the machined area. Bhattacharya et al. [17]
studied the surface characterization and material migration during surface modification of die
steels with silicon, graphite and tungsten powder in EDM process and further analyzed the
two output responses, micro-hardness and surface roughness.
From the above literature studies, it is observed that a lot of work has been undertaken by
various authors to investigate the various performance characteristics of WC material. But no
author found who perform the investigation for PM-EDM of WC alloy for micro-hardness
and surface roughness. This motivates the authors to perform a detail investigation for
powder-mixed EDM of WC alloy by using alumina and graphite powder. In this study, the
Taguchi method is used by to perform the experimentation and parametric optimization of
response characteristics; micro-hardness and surface roughness for PM-EDM of WC alloy.
Followed by investigation of signal-to-noise ratio for both the characteristics and at last
ANOVA analysis is used to find the most significant and contributing parameter.

3. EXPERIMENTAL DETAILS
In PMEDM process, powders are mixed into the dielectric fluid in the tank and to avoid the
powder to get mixed into the filtering system, a transparent bath like container (10 liters
capacity), called machining tank is placed in the work tank of EDM and the machining is
performed in this container (as shown in Figure 1). For better circulation of the powder mixed
in the dielectric, a stirrer is also used to shake the powder continuously in the box whose rpm
is controlled by a heavy duty regulator. Experimental work has been performed on CNC
EDM spark erosion Charmilles Technologies (Model no. ROBOFOR M20) as shown in
Figure 1. Tungsten carbide with composition, W-65.50%, Ti-15.47%, Co-10.07%, Nb-4.69%
and Cu-3.66%, is used as workpiece material. Electrolytic copper is used as tool and EDM oil
is used as working fluid.

Z-axis
servomotor

Stirrer
mechanism

PM-EDM
Tank

Figure 1 Experimental setup (Model no. T-3822)

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

3.1 SETTING OF THE PROCESS PARAMETERS AND THEIR LEVELS

To study the response characteristics i.e. micro-hardness (M-H) and surface roughness (SR)
of PM-EDM process, four input parameters used are (i) pulse-on, (ii) pulse-off, (iii) current
and (iv) powder. The various parameters and their levels are mentioned in Table 1.

Table 1Process parameters and their levels

Factors Process Parameter Level-1 Level-2 Level-3
A Pulse-on time (s) 15 50 100
B Pulse-off time (s) 10 50 75
C Current (A) 3 6 9
D Powders C Al2O3 -
C = graphite, Al2O3 = aluminum oxide, simple EDM = -

The constant input parameters used in the experiments are; open circuit voltage (135 5%),
polarity (+), tool (copper), machining time (10 min), powder concentration (15 gm/l). There
are four factors with three levels which have been finalized on the basis of pilot
experimentation and literature survey. The number of factors and their levels determine the
total degree of freedom (DOF) for the experiment. As degree of freedom for each factor is
given by K-1, where K is the number of level for each response, therefore the total degree of
freedom is 8; so according to Ross [18], OA L27 is capable to handle these factors. Table 2
shows the L27 OA experimental design used in the study, it also shows the values of M-H and
SR values obtained for all the 27 experiments with signal-to-noise ratio for each experiment.

Table 2 Taguchi L27 OA Experimental design and output values.

Sl. Pulse-on Pulse-off Current, Powder M-H, M-H, SR, SR,
no. Time, (s) Time, (s) (A) (HVN) (S/N ratio) (m) (S/N ratio)

1 15 10 3 C 1186 61.4817 0.674 -10.2377

2 15 10 6 Al2O3 1236 61.8404 0.769 -11.8435
3 15 10 9 - 1258 61.9936 0.898 -9.7992
4 15 50 3 Al2O3 1153 61.2366 1.036 -16.0418
5 15 50 6 - 1222 61.7414 1.039 -10.2910
6 15 50 9 C 1134 61.0923 0.531 -7.0437
7 15 75 3 - 1162 61.3041 1.446 -13.8745
8 15 75 6 C 1034 60.2904 1.932 -14.2193
9 15 75 9 Al2O3 1174 61.3934 0.836 -9.4843
10 50 10 3 C 1231 61.8052 0.774 -14.6639
11 50 10 6 - 1125 61.0231 0.928 -6.5267
12 50 10 9 Al2O3 1238 61.8544 0.485 -7.0437
13 50 50 3 C 1278 62.1306 1.132 -12.9084
14 50 50 6 - 1213 61.6772 0.949 -9.0050
15 50 50 9 C 1271 62.0829 1.269 -9.7992
16 50 75 3 - 1192 61.5255 0.882 -11.8657
17 50 75 6 C 1271 62.0829 0.688 -9.2779
18 50 75 9 Al2O3 1294 62.2387 0.861 -10.0485
19 100 10 3 C 1273 62.0966 0.989 -8.2324
20 100 10 6 Al2O3 1296 62.2521 0.640 -10.6296
21 100 10 9 - 1267 62.0555 0.528 -9.2180
22 100 50 3 Al2O3 1136 61.1076 0.936 -2.6067
23 100 50 6 - 1302 62.2922 1.826 -10.6805
24 100 50 9 C 1332 62.4901 1.421 -9.7710
25 100 75 3 - 1284 62.1713 0.763 -9.2779
26 100 75 6 Al2O3 1272 62.0897 1.064 -9.9662
27 100 75 9 C 1266 62.0487 1.237 -10.3703

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

3.2 MACHINING PERFORMANCE MEASUREMENT

3.2.1 Micro-hardness
The micro-hardness measurement is dependent on the diameter of the indentation on the
samples formed by the indenter. The indents are formed in the pyramid shaped, the use of a
diamond pyramid with the apex angle of 136 leads to the Vickers micro-hardness Hv (MPa)
[19]. Micro-hardness was measured on a computer interfaced micro hardness tester (Model
MVH-2) of Meta Tech Industries, Pune, India. Indent was measured with Quantimet software
using a load of 1kg for 25 seconds. Micro-hardness is measured at two places on all the 27
samples; one at the centre and other at the corner.
3.2.2 Surface roughness
Generally, surface roughness is measured in terms of arithmetic mean (Ra) which according
to the ISO 4987: 1999 defined as the arithmetic average roughness of the deviations of the
roughness profile from the central line along the measurement.
The surface roughness of the workpiece can be expressed in different ways like, arithmetic
average (Ra), average peak to valley height (Rz), or peak roughness (Rp), etc. In the study it
was measured by using the Perthometer (Model SJ-400 of Mitutoyo, Japan). The equipment
uses stylus method of measurement, has profile resolution of 12nm and measure roughness
up to 100m. A tracing length of 0.24 mm was used for analysis. Surface roughness is also
measured at two places on the all 27 samples, one in vertical and other in horizontal direction.

4. RESULTS AND DISCUSSIONS

In this chapter, the data of M-H and SR obtained from 27 experiments are analyzed by using
mean and S/N ratio graphs followed by response tables. At last, ANOVA analysis for mean
was performed to show the significant factors and their contributions in the study.
3.1 RESULT AND DISCUSSION FOR MICRO-HARDNESS
In order to see the effect of process parameters on the micro-hardness, experiments were
conducted using L27 OA. The experimental data is given in Tables 2.The average values of
micro-hardness for each parameter at levels 1, 2 and 3 for raw data and S/N data are plotted
in Figures 3a and b respectively.
M-H is the higher-the-better type of response characteristic. Therefore, higher values of
micro-hardness are considered to be optimal. Figure 2a and 2b shows the mean and S/N ratio
graph for micro-hardness.These graphs show that the value of micro-hardness found optimal
at pulse-on time (A3), pulse-off time (B1), current (C2) and powder (D1). It was observed that
with increase in pulse-on time and addition of graphite powder micro-hardness value
increases. This happens due to accumulation of high graphite powder during high discharging
on high pulse-on time and medium current values. At peak value of current, the disability in
machining process has been observed. Alumina powder has also helps to increase in micro-
hardness as compared to simple EDM process.
Response table for raw data (mean) and S/N ratio for M-H are shown in Table 3a and b. As,
M-H is higher-the-better response characteristic, hence higher value has been selected from
the response tables. According to response tables, pulse-on time is the most effective process
parameter followed by pulse-off time, powder and current. The most significant values are
highlighted by star (*) in response table. Residual plot is used to evaluate the data for the
problems like non normality, non-random variation, non-constant variance, higher-order
relationships, and outliers. It can be seen from Figures 3 that the residuals follow an
approximately straight line in normal probability plot and approximate symmetric nature of
histogram indicates that the residuals are normally distributed. Residuals possess constant
variance as they are scattered randomly around zero in residuals versus the fitted values.
Since residuals exhibit no clear pattern, there is no error due to time or data collection order.
ANOVA analysis for M-H is shown in Table 4 below. It concludes that pulse-on time

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR
JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE
CPIE-2016

(24.42%)) found most contributing for M-H

M followed by the pulse-off off time (16.18%), powder
(14.87%) and interaction effect of pulse-on
pulse time with pulse-off time (12.52%).

a b

Figure 2 Effect of process parameters upon micro-hardness

m

Table 3 Response table for (a) mean of raw data of M M-H,, (b) S/N ratio of M-H
M
(a) Response table for mean of raw data of M-H
Level Pulse-on
on Time, A Pulse-off Time, B Current, C Powder, D
1 1173 1257* 1226 1252*
2 1235 1241 1250* 1232
3 1270** 1190 1220 1216
Delta 97* 67 30 36
Rank 1 2 4 3
(b) Response table for S/N ratio of M-H
Level Pulse-on
on Time, A Pulse-off Time, B Current, C Powder, D
1 61.477 61.92* 61.75 61.92*
2 61.82 61.86 61.95* 61.79
3 62.07** 61.51 61.70 61.64
Delta 0.60** 0.41 0.25 0.28
Rank 1 2 4 3

Figure 3 Residual Plots for M-H

M based on S/N for 27 performed experiments

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR
JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE
CPIE-2016

Table 4 ANOVA for mean (raw data) of micro-hardness

Factors DF SS MS F % of contribution Status
Pulse-on Time, A 2 43011 21505.6 6.38 24.42
Pulse-off Time, B 2 28506 10249.9 4.21 16.18
Current, C 2 12032 4516.0 1.04 6.83
Powder, D 2 26194 8711.7 3.89 14.87
P-on Time P-off Time 4 22052 6380.2 3.58 12.52
P-on Time Current 4 7104 1776.0 1.05 4.03
P-on Time Powder 4 21957 5489.1 3.48 12.46
Residual error 18 20234 3372.3 11.49
Total 26 124252 100
S = 58.07, R
R-Sq = 83.7%, R-Sq(adj) = 69.8%
critical selected is 3.55, here represents a significant term and represents the insignificant terms
Here in both *F-critical

3.2 RESULT AND DISCUSSION FOR SURFACE ROUGHNESS

The experiments performed (shown shown in Table 2) provide the SR SR value for all the 27
experiments. The average values of surface roughness for eachach parameter at levels 1, 2 and 3
for raw data and S/N data are plotted in Figures 4a and b respectively.
Surface roughness is smaller-thethe-better
better response characteristics, therefore lower value of
surface roughness considered to be optimal. Response graphs shown in Figures 4a and b
shows that the surface roughness increases with increase in both pulse-on on time
tim and current
(input discharge energies). This happens because of increase in discharging and melting,
evaporating temperature which ultimately increases the material removal rate from workpiece
and makes the surface more rough. In powders, graphite powder gives us minimum value of
surface roughness as it stabilizes the machining process followed by alumina powder and
simple EDM process. Therefore
Therefore, according to the results, low pulse-onon time (A1), medium
pulse-off time (B2), low current (C1) and graphite powder (D1) found optimum parameter
setting for surface roughness. Residual plots for SR as shown in Figure 5 shows that the
experimental results are good and data are normally distributed about the centre line. S SR is
lower-the-better
better response characteristic
characteristic;; hence the lower value has been selected from the
response table. Response table (Table 5a and b) shows that current is the most most influencing
parameter for SR R followed by powder, pulse-on time and pulse-off off time. The significant
values are highlighted by star
tar in response table.

a b

Figure 4. Effect of process parameters upon mean of surface roughness

6
 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR
JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE
CPIE-2016

Table 5 Response table for (a) mean of raw data of SR, R, (b) S/N ratio of SR
(a) Response table for mean of raw data of SR
Level Pulse-on
on Time, A Pulse-off Time, B Current, C Powder, D
1 3.498* 3.618 3.191* 3.389*
9*
2 3.607 3.511* 3.449 3.644
44
3 3.791 3.733 4.212 3.769 9
Delta 0.293 0.222 1.021* 0.380
380
Rank 3 4 1 2
(b) Response table for S/N ratio of SR
Level Pulse-on
on Time, A Pulse-off Time, B Current, C Powder, D
1 -10.926* -11.469 -10.209* -10.757
57*
2 -11.327 -11.032* -11.271 -11.451
51
3 -11.872 -11.594 -12.675 -11.817
17
Delta 0.946 0.562 2.466* 1.06
Rank 3 4 1 2

Figure 5 Residual Plots for SR based on S/N for 27 performed experiments.

experiments

ANOVA analysis for SR R is performed at 95% confidence interval, represented in Table 6. It

shows the current is the most contributing factor (24.71%), followed by pulse pulse-off time
(19.30%) and powder (19.08%). Rest of the factors are found insig
insignificant
nificant for the study.
Table 6 ANOVA for mean (raw data) of surface roughness
Factors DF SS MS F % of contribution Status
Pulse-on Time, A 2 3.9641 2.30467 2.19 7.54
Pulse-off Time, B 2 3.7212
.7212 1.36060 1.34 7.08
Current, C 2 12
12.5267 5.26336 5.16 23.85
Powder, D 2 11
11.1505 4.07523 4.07 21.23
P-on Time P-off Time 4 2.0506
.0506 0.26266 0.49 3.90
P-on Time Current 4 10.8346 3.70865 3.58 20.63
P-on Time Powder 4 2.3194 0.57985 0.55 4.41
Residual error 18 6.3013 1.05022 11.94
Total 26 52.5136 100
S = 2.025, R
R-Sq = 89.3%, R-Sq(adj) = 58.4%
critical selected is 3.55, here represents a significant term and represents the insignificant terms
Here in both *F-critical

7
 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

4. CONCLUSION
This paper has discussed the powder mixed EDM of tungsten carbide by using Taguchi
approach. Taguchi method has been used to determine the main effects, significant factors
and optimum machining condition to the performance of EDM. Graphite and alumina
powders are used in working fluid, whereas graphite powder seems suitable for high M-H.
Pulse-on time and pulse-off time found most significant in case of micro-hardness. Whereas,
current and powder found most influencing for the surface roughness. ANOVA analysis
shows the percentage contribution of each factor for the study.

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

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