This paper presents an experimental investigation on effect of welding parameter to repair welding of dissimilar material using Gas Metal Arc Welding (GMAW) machine. Taguchi Method has been used to analyse the statistical analysis by using Minitab Software. Repair welding getting more popular nowadays due to saving cost and prolong the material service life. The effect of repair welding of dissimilar material on mechanical properties have been studied. Statistical analysis using Taguchi Method by Minitab Software with three times repetition of L9 orthogonal array. Setting up GMAW machine with current (150A-170A), voltage (17V-21V) and jig rotational speed (50rpm-100rpm) were prepared with 3.00mm of Stainless Steel 304L and 3.60mm Carbon Steel 1387.Result shows that voltage gave a huge impact to tensile testing and micro hardness of second repair welding. While current and jig rotational speed gave less impact to responses. The benefit shown have caused repair welding to be accepted and applied in the industry. Regular and total maintenance is able to contribute to the savings while producing good preventive maintenance schedule.
The machining ability of electrical discharge machining (EDM) die-sinking on aluminium LM6 (Al-Sil2) as a new material is investigated.The objective of this paper is to determine the relationship between the machining parameters which are pulse-on time, pulse-off time and peak current on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Tungsten copper tool of diameter 10mm was chosen as an electrode. Design of experiment using Taguchi method was used to develop experimental matrix and optimize the MRR, EWR and Ra. The analysis was done using the Minitab software. It is found that the current and pulse on time are significantly affected the MRR, EWR and Ra while pulse off time and voltage are less significant factor that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.
Abstract. This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6. IntroductionBrass is one of the electrical conductive materials. Today, however, brass is seldom used as an electrode in EDM die sinking due to its high wear rate but it still good for machining materials for high speed small hole machines because it exhibits higher degree of stiffness and easier to machine than copper [1]. Even though, brass already used as an electrode but it is still not tested for cutting aluminium alloys LM6. It is known that LM6 which aluminium containing 12% silicon has good resistance to corrosion and excellent cast ability [2]. It is widely used in many fabrication devices due to its characteristics properties such as applications for motor housings, manifolds, marine components and pumping cases. Further, LM6 is also appropriate where sometimes castings require to be welded.Usually in die tooling, when materials used is hard, it becomes better for die tooling, however it would be difficult to cutting using conventional cutting tools [3]. Therefore, some others electrode materials were tested against the aluminium alloys LM6 like copper tungsten [4], copper [5] and graphite [6] which has yielded a good experimental result. A special advantage of EDM die-sinking offers compared to conventional machine where materials removed without any contact between electrode and workpiece. As a result, problems of vibration and mechanical stress can be eliminated during machining process [7].Even though, the use of die-sinking EDM focused on the cutting material having conductivity of an electric, the process capability of cutting alloys materials, becomes more challenges regardless of their hardness and toughness [8]. The most advantage of EDM die-sinking machine is that it can cut electrical conductivity material, free from burrs especially for stamping die that can be produced by EDM die-sinking with accurate dimension, low cost and fast processes [9].
Abstract. The stirred tank is widely used in many industries to obtain the desired type of fluid mixing. In the context of mixing process, two different fluids and have a different properties will mix in a single equipment to produce another fluid with a new property. In this research, a new approach of stirred tank which is containing a new design of baffles and impellers was proposed for fluid mixing. The new design of baffles and impellers that proposed here are used a fractal pattern for both parts in the stirred tank. Implementing a fractal pattern for baffles and impellers in stirred tank believe will influence the flow characteristic inside the stirred tank, hence will improve a mixing performance. In order to investigate the kinds of flow properties, a Particle Image Velocimetry (PIV) technique with 1 µm seeding particle was used. Four configurations were tested which are normal baffles and normal impellers, normal baffles and fractal impellers, fractal baffles and normal impellers, and the last configuration is fractal baffles and fractal impellers. In this study, dual Rushton impellers with 4 blades were used with the configurations mentioned. The result shows the significant flow field capture by PIV measurement on each configuration. By using fractal impeller some vortex are shown in the tank and high velocity vector on flow field compare with normal impeller while normal baffles gives high velocity vector depends on the configuration were used. From the results, it was showed that the fractal design can give a certain level of mixing efficiency in stirred tank. The PIV technique also gives good flow visualization in order to determine the flow pattern in stirred tank with a new concept of baffles and impellers.
The machining ability of Electrical Discharge Machining (EDM) die-sinking on material characteristics of LM6 (Al-Sil2) is studied. This is due to the machining process on sharp edge, pocket, deep slot and micro hole cannot be performed by milling and turning machine. The objective of this paper is to determine the relationship between the machining parameters such as pulse on time, pulse off time, peak current and voltage on material removal rate (MRR) that are electrode wear rate (EWR) and surface roughness (Ra). Graphite tool of diameter 15mm was chosen as an electrode. Taguchi method is used as analysis technique to develop experimental matrix that is used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that the current and pulse off time are significantly effected the MRR, EWR and Ra while pulse on time and voltage are less significant factors that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.
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