EDM (Electrical Discharge Machining) is a common non-traditional machining technique for manufacture geometry parts made of intricate or extremely rigid metals that are challenging to manufacture using conventional manufacturing techniques. Electrical discharge machining by utilizing electrical discharge erosion, classify the meaning of material removal (MR). This paper's main objective is to discuss the ideal EDM parameters in order to use high-speed steel as workpiece AISI M2 and with using brass & copper as electrodes. Pulse on-time are (100, 150, and 200 µs), Current (10, 24 and 42 A) and Pulse off-time (4, 12 and 25 µs) are the input parameters effect on the material removal rate (MRR) used in the experimental work. The present study's findings shown that the highest MRR with using copper & brass as electrodes with pulse on-time 200 µs, pulse off-time 12 µs and current 42 A, at (0.31284 g/min and 0.18769) respectively, and the lowest average value of the removed material was when evaluating current 10 A, Ton is 100 µs, Toff is 4 µs, at (0.05451g/min and 0.01898 g/min) respectively.
In machining operations, surface roughness (Ra) is an essential measure of product quality. It is determined by the cutting settings. The parameters that have been worked on are the Feed (F) (0.72, 0.88, 0.96, 1.12 mm/min), depth of cut (DOC) (0.5mm), and spindle speed (N) (545, 710, 1000, 1400 r.p.m). Three types of ferrous metals were employed in this study low-carbon steel St 3, medium-carbon steel St 45, and high-carbon steel Y8. According to the data, the optimal operating condition for obtaining the best surface roughness is 1.119 µm for low-carbon steel. St 3 from the product is by employing the following cutting settings for the cutter (feed 0.72 = mm/rev), (DOC= 0.5mm), and (machine speed =1400 rpm). But when using the cutting variables (feed 1.12 = mm/rev), (DOC = 0.5mm), and (machine speed = 545 rpm) for high-carbon steel Y8, gives the highest surface roughness is 4.999 µm . The experimental findings indicate that the surface roughness of turned components is considerably affected by cutting settings and machine equipment. According to the results of this study, increasing spindle speed lowered the Ra of the turned components, but rising feed increased the surface roughness. The value acquired by this approach will benefit other researchers for future work on tool vibrations, cutting forces, and so on.
Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.
In this work prepared and study a polymer composite, where use polyester resin with asbestos fiber ratio (5%, 10% and 15%). First study effect of changing reinforcement percentage by asbestos fiber on coefficient thermal conductivity (k) of polymer composite. Result show decrease in the coefficient thermal conductivity (k) of composite materials with increase of weight percentage of asbestos fiber. Second, study effect of it above reinforcement ratio on the some of mechanical properties (Impact, tensile, fracture and hardness) for polymer composite. The result indicate increase value of mechanical properties with increase weight percentage of asbestos fiber. The impact strength was (2.7 kj/m2) for pure resin where reach to maximum value (7.83 kj/m2) at 15wt% of fiber .Hardness and tensile reach to maximum value at 15% weight percentage for asbestos fiber. The result illustrate improvement mechanical properties after reinforcing by asbestos fiber and these properties rises with increased in reinforcement percentage.
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