Parametric Optimization of Electric Discharge Machining for AISI 1045 Steel: A Comprehensive Study

Muhammad Mansoor Uz Zaman Siddiqui; Syed Amir Iqbal; Ali Zulqarnain; Adeel Tabassum

doi:10.36561/ING.28.15

Authors

Muhammad Mansoor Uz Zaman Siddiqui NED University of Engineering and Technology, Pakistán https://orcid.org/0009-0007-8992-7601
Syed Amir Iqbal NED University of Engineering and Technology, Pakistán https://orcid.org/0000-0002-6812-6238
Ali Zulqarnain NED University of Engineering and Technology, Pakistán https://orcid.org/0000-0003-2762-5409
Adeel Tabassum NED University of Engineering and Technology, Pakistán https://orcid.org/0009-0006-9375-1090

DOI:

https://doi.org/10.36561/ING.28.15

Keywords:

Electric Discharge Machining, AISI 1045, Parametric Optimization, Material Removal Rate, Electrode Wear Rate, Surface Roughness, Machining Time, Response Surface Methodology, ANOVA, Base Radius

Abstract

This study investigates the optimization of Electric Discharge Machining (EDM) parameters for AISI 1045. It is a medium carbon steel which is commonly used in automotive and aerospace industries because of its balanced strength, toughness and machinability. However, achieving optimal machining efficiency with excellent surface finish in short time and without wasting excess material with EDM remains a challenge at large. The research focuses on optimizing key EDM input parameters like current (LV), voltage (HV), pulse on time (Ton) and pulse off time (Toff), to improve machining time (Tm), material removal rate (MRR), electrode wear rate (EWR), surface roughness (Ra) and base radius (R). Full factorial design and Response Surface Methodology (RSM) were used to conduct experiments, and ANOVA was employed to identify the most significant factors influencing the output responses. Multi-objective optimization was performed through the desirability function and the findings were validated by repeated experiments. The results showed that pulse on time (Ton), its interaction with pulse off time (Toff) and the three-factor interaction between current (LV), Ton and Toff were the most significant factors affecting machining performance. Optimizing these parameters reduced machining time (Tm) to 623.21 seconds thus significantly improving EDM efficiency. The material removal rate (MRR) was maximized at 0.0173 g/min resulting in considerable increase in material removal efficiency. The electrode wear rate (EWR) was minimized to 0.0088 g/min, which prolongs electrode life and reduces operational costs. Surface roughness (Ra) was improved to 0.0253 mm, ensuring a high-quality surface finish. The base radius (R) was successfully optimized to 1.5298 mm, aligning closely with the desired target of 1.5 mm thus ensuring dimensional accuracy. This investigative study of optimization of parameters for EDM of AISI 1045 material is extremely significant for automotive and aerospace industries that rely on precision machining, as the optimized EDM parameters lead to improved efficiency, reduced material waste and enhanced product quality. These findings offer valuable insights for improving EDM processes, particularly in sectors requiring complex geometries and high precision, such as automotive and aerospace manufacturing.

Downloads

Download data is not yet available.

References

A Review of Recent Application of Machining Techniques, based on the Phenomena of CNC Machining Operations. I.P. Okokpujie, C.A. Bolu, O.S. Ohunakin, E.T. Akinlabi, D.S. Adelekan. s.l. : Elsevier, 2019, Procedia Manufacturing, Vol. 35, pp. 1054-1060. ISSN 2351-9789.

Improving the machining performance of polymer hybrid composite by abrasive water jet machining for precise machining. Kumar, K. Nirmal, and P. Dinesh Babu. s.l. : Springer Nature, 2024, Arabian Journal for Science and Engineering. 2191-4281.

Ultrasonic machining: a case study. Gilmore, Randy. 1-2, s.l. : Elsevier, 1991, Journal of Materials Processing Technology, Vol. 28, pp. 139-148. ISSN 0924-0136.

Mechanical behavior of carbon fiber-reinforced plastic during rotary ultrasonic machining. Abdelkader Slimane, Mohammed Chaib, Sidahmed Slimane, Sidahmed Dahmane, Anas Abderrahmane Lahouel, Ahmed Guelailia, Kaddour Bahram, Said Kebdani & Benattou Bouchouicha. 11, s.l. : Springer Nature, 2024, The International Journal of Advanced Manufacturing Technology, Vol. 130, pp. 5345-5357. 1433-3015.

A comprehensive review of studying the influence of laser cutting parameters on surface and kerf quality of metals. Muhammad Alsaadawy, Montasser Dewidar, Ahmed Said, Ibrahem Maher & Taher A. Shehabeldeen. 3, s.l. : Springer Nature, 2024, The International Journal of Advanced Manufacturing Technology, Vol. 130, pp. 1039-1074.

Innovation Study for Laser Cutting of Complex Geometries with Paper Materials. A. Happonen, A. Stepanov, H. Piili, A. Salminen. s.l. : Elsevier, 2015, Physics Procedia, Vol. 78, pp. 128-137. ISSN 1875-3892.

Electric Discharge Machining of Ti6Al4V ELI in Biomedical Industry: Parametric Analysis of Surface Functionalization and Tribological Characterization. Farooq, Muhammad Umar, Saqib Anwar, Haider Ali Bhatti, M. Saravana Kumar, Muhammad Asad Ali, and Muhammad Imam Ammarullah. 12, s.l. : MDPI, 2023, Materials, Vol. 16. 1996-1944.

Optimization design for die-sinking EDM process parameters employing effective intelligent method. Van Tron Tran, Minh Huy Le,Minh Thai Vo,Quoc Trung Le,Van Huong Hoang,Ngoc-Thien Tran,Van-Thuc Nguyen,Thi-Anh-Tuyet Nguyen,Hoai Nam Nguyen,Van Thanh Tien NguyenORCID Icon &Thanh Tan Nguyen. 2, s.l. : Taylor & Francis, 2023, Cogent engineering, Vol. 10.

Experimental Study on Electrochemical Machining with Electrolyte Confined by Absorption Material. Wataru Natsu, Junfeng He, Yu Iwanaga. s.l. : Elsevier, 2020, Procedia CIRP, Vol. 87, pp. 263-267.

A review on recent achievements and challenges in electrochemical machining of tungsten carbide. Mohammed Asmael, Amin Memarzadeh. 1, s.l. : Queens University Belfast, 2023, Archives of Advanced Engineering Science, Vol. 2, pp. 1-23.

To Study the Effect of Process Parameters for Minimum Surface Roughness of Cylindrical Grinded AISI 1045 Steel. Singh, T., Goyal, K., Kumar, P. 3, s.l. : Horizon Research Publishing Corporation, 2014, Manufacturing Science and Technology, Vol. 2, pp. 56-61.

Surface texturing of the carbon steel AISI 1045 using femtosecond laser in single pulse and scanning regime. Stašić J, Gaković B, Perrie W, Watkins K, Petrović S, Trtica M. 1, s.l. : Elsevier, 2011, Applied Surface Science, Vol. 258, pp. 290-296. ISSN 0169-4332.

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying. Garba, E., et al. 9, s.l. : MDPI, 2023, Machines, Vol. 11. 906.

Experimental Investigations of Surface Modification of AISI 1045 Die Steel by Electro Discharge Machining Process. Harjot Singh, S.S. Banwait. 4, s.l. : Science and Education Publishing Co., 2016, American Journal of Mechanical Engineering, Vol. 4, pp. 131-141.

Prediction and optimization of performance measures in electrical discharge machining using rapid prototyping tool electrodes. Mahapatra, Anshuman Kumar Sahu & Siba Sankar. s.l. : Springer Nature, 2021, Journal of Intelligent Manufacturing, Vol. 32, pp. 2125-2145.

Reviewing performance measures of the die-sinking electrical discharge machining process: challenges and future scopes. Shastri, R.K., et al. 384, s.l. : MDPI, 2022, Nanomaterials, Vol. 12.

Process optimization for rapid manufacturing of complex geometry electrical discharge machining electrode. Singh J, Pandey PM. 1, s.l. : Sage Journals, 2020, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, Vol. 231, pp. 66-81.

Influence of ZnO nanoparticle addition and spark peak current on EDM process of AISI 1045, AISI 4140, and AISI D3: MRR, surface roughness, and surface topography. K., Masoud Pour & S. Ehsan Layegh. s.l. : Springer Nature, 2022, The International Journal of Advanced Manufacturing Technology , Vol. 122, pp. 3703-3724.

Electrical Discharge Machining (EDM): A Review. Banu, A., & Ali, M. Y. 1, s.l. : Deer Hill Publications, 2016, International Journal of Engineering Materials and Manufacture, Vol. 1, pp. 3-10. E-ISSN: 0128-1852.

Wire EDM process optimization for machining AISI 1045 steel by use of Taguchi method, artificial neural network and analysis of variances. Ahmed A. A. Alduroobi, Alaa M. Ubaid, Maan Aabid Tawfiq & Rasha R. Elias. 6, s.l. : Springer Nature, 2020, International Journal of System Assurance Engineering and Management , Vol. 11, pp. 1314-1338. 0976-4348.

Study on AISI1045 material for various applications: an over view. Vishnuja, U., Bhaskar, GB. 2, s.l. : Research India Publivcations, 2018, International Journal of Engineering and Manufacturing, Vol. 8, pp. 125-144. ISSN 2249-3115.

Investigation on the influence of machining parameters when machining tool steel using EDM. C.H. Che Haron, B.Md. Deros, A. Ginting, M. Fauziah. 1, s.l. : Elsevier, 2001, Journal of Materials Processing Technology, Vol. 116, pp. 84-87.

Optimization of Machining Parameters for Surface Roughness in EDM of AISI 1045 Based on Taguchi Technique. Agarwal, Subodh Kumar and Sanjay. Vancouver, British Columbia, Canada : ASME, 2012. ASME International Mechanical Engineering Congress & Exposition. Vol. 3. ISBN: 978-0-7918-4427-4.

Optimization of wire electric discharge machining (WEDM) process parameters for AISI 1045 medium carbon steel using Taguchi design of experiments. Zaman, Uzair Khaleeq uz, Usman Ahmed Khan, Shahid Aziz, Aamer Ahmed Baqai, Sajid Ullah Butt, Danish Hussain, Ali Siadat, and Dong Won Jung. 21, s.l. : MDPI, 2022, Materials, Vol. 15. 7846.

Variation of surface roughness on electrical discharge machining die sinking caused of different electrode material, current, and on Time. Darsin, M., Y. Hermawan, and A. Rachmat. Bali, Indonesia : Asian Federation of Biotechnology, 2011. 12th International Conference on Quality in Research. pp. 956-961. ISSN 114-1284.

Application of Response Surface Methodology For Determining MRR and TWR Model In Die Sinking EDM of AISI 1045 Steel. M. B. Patel, P. K. Patel, J. B. Patel, B. B. Patel. 6, 2012, International Journal of Engineering Research and Applications, Vol. 2, pp. 1227-1231. ISSN: 2248-9622.

Analysis of material removal rate and electrode wear in sinking EDM roughing strategies using different graphite grades. F Klocke, M Schwade, A Klink, D Veselovac. [ed.] J.-P. Kruth B. Lauwers. Leuven, Belgium : Elsevier, 2013. Proceedings of the Seventeenth CIRP Conference on Electro Physical and Chemical Machining (ISEM). Vol. 6, pp. 163-167. ISSN 2212-8271.

Modeling and analysis of MRR, EWR and surface roughness in EDM milling through response surface methodology. Khan, A.K.M. Asif Iqbal and Ahsan Ali. 4, s.l. : Science Publications, 2010, American Journal of Engineering and Applied Sciences, Vol. 3, pp. 611-619. ISSN 1941-7020 .