Professor of School of Engineering, Design and Built Environment, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.
Abstract—Non-Conventional methods are widely used due to their time saving process with superior
quality. In non-conventional machining process we use thermal energy provided by a heat source,
to melts and (or) vaporizes the volume of the material to be removed. Among thermal removal
methods, Electric discharge machining is most widely used method for making tools such as
Die steel, tool steel which are difficult to machine by simple methods. It was found that
considerable research has been done on various aspects of electrical discharge machining of
low carbon steels, carbides and a few die steels such as AISI D2, H13, haste alloy etc. steel,
with different types of electrodes such as ZrB2-Cu, Cu, CuW etc. but sufficient data has not
available on H-11 steel. H-11 is a Die tool steel. H-11 offers high corrosion resistance, wear
strength and high hardness. It is widely used in extrusion tools, forging dies, stamping dies, etc.
Hence there is a need to investigate the machining of this material with copper and copper
tungsten (CuW) electrodes (made through powder metallurgy technique). A L18 Taguchi’s standard
orthogonal array is used for experimental design by varying different input machining parameters
such as discharge current, gap voltage, duty cycle, polarity, retract distance and their effect on
Material Removal Rate ( MRR). It was found that Material Removal Rate is maximum with
conventional copper electrode with peek current (14A) at voltage (40V) and duty cycle (0.92) in
Index Terms—Electrical Discharge Machining (EDM), Powder Metallurgy (PM) Taguchi method,
Material Removal Rate (MRR)
Cite: Sumesh Kapila and Dinesh Kumar, "Study of Material Removal Rate of H11 Die Tool Steel during Electric Discharge Machining at Normal Polarity," International Journal of Mechanical Engineering and Robotics Research, Vol. 3, No. 3, pp. 405-415, July 2014.
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