In the present research, composite electrode (Cu-Mn) manufactured through powder metallurgy has been used to machine hot die steel (H11) by Electrical Discharge Machining (EDM) process with the aim of inducing manganese and carbon into the machined surface. Such alloying is expected to improve the microhardness and other surface characteristics. Best level of process parameters for better surface finish and high microhardness are found using Taguchi method. Six processing parameters are considered and their significance is investigated by analysis of variance (ANOVA).Techniques like SEM, EDS and XRD are used to ascertain the surface characteristics.Surface machined at optimum process conditions for microhardness shows 93.7% improvement due to formation of cementite, ferrite and manganese carbide phases.Surface roughness having Ra value of 3.11 µm has been achieved.
This research work has been completed by concentrating on the structure of inserts for foot orthosis fabricated by utilizing rapid prototyping technology. Thermoplastic elastomer and thermoplastic polyurethane are the most commonly used materials that are being used in customized three-dimensional printed orthotic insoles, which are comfortable and prevent the user in many foot disorders. Thermo-softening viscoelastic polymers, explicitly Filaflex and Ninjaflex, have been printed by utilizing Flash Forge three-dimensional printers to evaluate the mechanical properties of specimens with alterations of the percentage rate fill-up design replicas. The results are compared on the basis of hardness test, flexural/bending test, and tensile test using Durometer and Universal Testing Machine (UTM). It has also been observed that the most significant effecting factor is infill density.
Electrical discharge machining is a non-conventional material removal process; recently, efforts have been made to use it as a surface alloying/modifying method. This study investigates and compares the micro-hardness of the surface machined by electrical discharge machining process using composite tool electrode (copper-chromium-nickel) manufactured by powder metallurgy and conventional copper tool. Design of experiment is used to find the best level of process parameters in order to achieve high micro-hardness. The machined surfaces are subsequently analyzed using different techniques like scanning electron microscopy, X-ray diffraction and energy-dispersive spectroscopy to ascertain the surface characteristics. Results indicate that the micro-hardness of the alloyed surface formed by powder metallurgy tool electrode is improved by 96.3% as compared to base material and 65.7% as compared to the surface machined by conventional copper electrode. Energy-dispersive spectroscopy of the surface machined using powder metallurgy electrode confirms significant material migration from tool and dielectric to the machined surface. The X-ray diffraction shows the formation of cementite (Fe 3 C), intermetallic compound of iron, chromium and nickel (FeCrNi) and chromium carbide (Cr 7 C 3) on the surface machined using powder metallurgy electrode.
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