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.
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