Surface is very critical from quality point of view which affecting the life and the performance of products. Surface properties can be improved by number of methods, but electroplating is preferred because of its enhanced results at lower cost. In this work nickel chrome is selected for experimentation as it is widely used in industry especially in automotive sectors for plating many of the automotive components. The electroplating of nickel chrome not only improves the surface properties but also aesthetics of the component which is also a vital part of automobile requirement. Experiments are planned by Taguchi L16 orthogonal array and effect of density of solutions and time for processes at two levels on thickness variation is studied. Mathematical model were developed by regression analysis for thickness variation. Genetic Algorithm is used for optimization of process parameters. It was observed that the effect of time is more dominating for the thickness variation.
Electric discharge machining (EDM) is a non-traditional machining process; it is a well established machining option in many manufacturing industries throughout the world. There are no physical cutting forces between the tool and work piece while removing the material, it only uses thermal energy to machine electrically conductive parts regardless of hardness has been its distinctive advantage in the manufacturing industries. Inconel 718 is one of the alloy that have relatively poor machinability, due to its work hardening nature, retention of high strength at high temperature and low thermal conductivity. This paper presents the results of experimental work carried out in electrical discharge machining of Inconel 718 using two different tool materials namely copper and brass. The outline of this work is to optimize the process parameters like current, voltage and pulse on time for maximum material removal rate and minimum tool wear rate. The response surface analysis is used for the data analysis while RSM's D-optimal method is used to solve the multi response optimization. It is observed that copper electrode perform better than brass for the tested work material.
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