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    Investigation into the Electrical Discharge Machining Parameters of DIN 2767 Tool Steel Using Taguchi Method
    (Univ Science & Technology Southern Philippines, 2021) Fatatit, Abubaker Yousef; Kalyon, Ali
    Electrical discharge machining (EDM) is one of the most crucial non-traditional machining methods used in molds and dies manufacturing, and conductive materials machining, which are difficult to machine by traditional methods. The EDM performance is affected by several machining parameters with different contribution percentages. In this study, the experimental investigations were conducted on DIN 2767 tool steel using CuCrZr, Cu and CuCo1Ni1Be (CNB) electrodes. The most influential process parameters were focused on to improve the EDM performance. The value of the process parameters and their levels were discharge current (6, 12 and 25 A), pulse-on time (50, 200 and 800 mu s) and pulse-off time (50, 200 and 800 mu s). Optimal levels of machining process parameters were obtained by employing the Taguchi L-27 orthogonal arrays. The experimental results showed that the optimal combination of the machining parameters for maximum material removal rate was A(3)B(2)C(1) using a CNB electrode. For minimum tool wear rate, the optimal parametric combination was A(1)B(3)C(1)( )and Cu electrode. The optimal parametric combination was A(1)B(3)C(3) and CuCrZr electrode for minimum surface roughness. The study further revealed the relation and interaction effect between process parameters for the performance measures. Lastly, the process parameters affected and changed the DIN 2767 tool steel workpieces' surface integrity as evidenced by the scanning electron microscopy images.
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    INVESTIGATION THE EFFECT OF EDM PROCESS PARAMETERS ON MACHINING PERFORMANCE OF DIN1.2767 TOOL STEEL
    (2022-06) Fatatit, Abubaker Yousef
    Accompanying the technological development and the advancement in the industry, the demand for materials with superior properties such as high strength, hardness and toughness is increasing. This made it difficult or impossible to cut these materials by conventional methods. Electric discharge machining (EDM) is one of the most important unconventional machining methods that have the ability to cut electrically conductive materials regardless of their mechanical properties. DIN1.2767 tool steel has wide application in the industry due to its good mechanical properties such as high toughness, good through-hardenability, high impact strength and pressure resistance. This study aims to investigate the effect of process parameters on EDM performance of DIN 1.2767 tool steel. The process parameters and their levels were electrode materials (Cu-Cr-Zr, Cu, CNB, NSS and B2), discharge current (Ip) (6, 12 and 25 A), pulse on-time (Ton) (50, 200 and 800 ?s) and pulse off-time (Toff) (50, 200 and 800 ?s). Surface crack density (SCD) and white layer thickness (WLT) were investigated by Scanning Electron Microscopy (SEM). Data analysis and the contribution of the process parameters were statistically evaluated using Analysis of Variance (ANOVA). The experimental results identified the set of process parameters that achieve the optimal EDM performance measures, the effect of each parameter on the performance measures, and the parameter interactions for the performance measures. However, Ip was the most dominant parameter affecting Material Removal Rate (MRR), followed by Toff. The highest material removal rate can be achieved by setting parameters on NSS electrode, Ip (25A), Ton (200µs) and Toff (50 µs). Ip has the highest effect on Tool Wear Ratio (TWR) followed by Ton and the minimal TWR was at Cu electrode Ip (6A), Ton (800 µs) and Toff (200µs). Ton was the most dominant parameter affecting Surface Roughness (SR), followed by Ip. The optimal surface finish was obtained at setting parameters B2 electrode, Ip (6A), Ton (800µs) and Toff (800µs). For the Overcut (OC), electrode material was the most significant parameter followed by Ip and the minimal OC was at NSS electrode, Ip (12A), Ton (50 µs) and Toff (800µs). Ton was the most significant parameter affecting WLT, followed by Ip and the minimal WLT was determined at using CNB electrode, Ip (25A), Ton (50 µs) and Toff (200µs) and the most dominant factor for SCD was Ton followed by electrode material and the best surface free of cracks attained at utilizing CNB electrode, Ip (25A), Ton (50 µs) and Toff (50µs).
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    Overcut Optimization in Machining of DIN 1.2767 Tool Steel with Electro Erosion Technique
    (2025) Fatatit, Abubaker Yousef; Kalyon, Ali
    Electro discharge machining is an energy based method that can cause fast electrode wear and dimensional errors. This study aimed to identify the optimum process parameters for processing 1.2767 steel using copper-based electrodes. The Taguchi optimization approach was used, and 18 pieces of 1.2767 steel were prepared for the experiments. The electrodes used were CuCoNiBe and CuNi 2 SiCr, and the electrode surfaces were sanded and polished before processing. The results showed that the CuNi 2 SiCr electrode produced the lowest overcut value of 0.07 mm, while the CuCoNiBe electrode had the highest observed overcut value of 0.320 mm. The discharge level had the most significant impact on overcut, while the type of electrode had the least. The optimal parameters for the CuNi 2 SiCr electrode were 12 A discharge current, 50 µs pulse duration, and 800 µs pulse off time. The processing under ideal conditions resulted in an overcut measurement value of 0.05 mm. Elektro erozyon ile işleme, hızlı elektrot aşınmasına ve boyutsal hatalara neden olabilecek enerji tabanlı bir işleme yöntemidir. Bu çalışma, bakır bazlı elektrotlar kullanarak 1.2767 çeliğini işlemek için optimum işlem parametrelerini belirlemeyi amaçlamıştır. Taguchi optimizasyon tekniği kullanılarak deneyler için 18 adet 1.2767 çeliğinden işparçası hazırlanmıştır. İşleme deneylerinde CuCoNiBe ve CuNi 2 SiCr elektrot kullanılmıştır ve elektrot yüzeyleri işlemeden önce zımparalanarak parlatılmıştır. Çalışma sonucunda CuNi 2 SiCr elektrot ile en düşük yanal açıklık değeri olan 0.07 mm, CuCoNiBe elektrod ile en yüksek yanal açıklık değeri olan 0.320 mm elde edilmiştir. Boşalım akımı, yanal açıklık üzerinde en önemli etkiye sahipken, elektrot tipi en az etkiye sahip parametre olmuştur. CuNi 2 SiCr elektrot için optimum işlem parametreleri 12 A boşalım akımı, 50 µs vurum süresi ve 800 µs bekleme süresi olarak belirlenmiştir. Optimum işleme şartında, yanal açıklık değeri 0.05 mm olarak elde edilmiştir.