TRIZ based Innovation in Electric Discharge Machining for improving productivity

Abstract

Aluminium alloys are among the most widely used engineering metals in commercial applications, ranking third after steel and copper. However, machining complex, intricate, low radius, and precise shaped Aluminium alloy products can be challenging. Electric Discharge Machining (EDM) is a popular technique used for this purpose, but recent research and field surveys have shown that cutting Aluminium with EDM can have detrimental effects.

To improve productivity and overcome the challenges of cutting Aluminium with EDM, an innovative approach using TRIZ has been developed. This approach involves conceiving and developing a setup to use abrasives with EDM, which can significantly enhance the machining process. By combining the benefits of EDM with abrasives, it is possible to achieve precise and efficient machining of Aluminium alloys without compromising the quality of the finished product. The TRIZ-based approach also enables the development of more advanced and sophisticated EDM setups that can handle a wide range of complex shapes and sizes, further enhancing productivity and efficiency.

In this study, we aim to investigate the benefits of a hybrid machining process and compare it to standard EDM. We vary the main process parameters to explore their effects on Material Removal Rate (MRR), Tool Wear Rate (TWR), and surface finish. We also use various abrasives to evaluate their impact on the machining process.

Findings reveal that the hybrid process can increase MRR by between 3% and 50%, depending on the type of abrasive used. At the same time, TWR is reduced from 73% to 6%, indicating a significant improvement in tool life. Furthermore, the surface finish is observed to be much smoother than that achieved through standard EDM.

Based on these results, we can confidently assert that the developed hybrid process meets the requirements of modern manufacturing applications. By combining the benefits of EDM with abrasives, it is possible to achieve higher machining efficiency and accuracy while reducing tool wear and improving surface finish. These advantages make the hybrid process an excellent choice for industries that require precise and efficient machining of complex components.