Experimental Investigation on Surface Characteristics in Powder-Mixed Electrodischarge Machining of AA6061/10%SiC Composite

Self Cite

This paper presents the experimental investigation on tool wear rate (TWR) in power mixed electrical discharge machining (PMEDM) of aluminium 6061 alloy reinforced with 10% silicon carbide particles (AA6061/10%SiC p Composite). Composite material is fabricated by mechanical stir casting process and further characterized by SEM and EDS.Tungsten powder with concentration of 4gm/ltr is mixed in the dielectric fluid. To know the influence of powder suspension in dielectric fluid on TWR, comparative study is done on the basis of experiments performed using basic EDM and powder mixed EDM process.Experiments have been designed as per central composite rotatable design (CCRD) using response surface methodology (RSM) approach. Four process parameters namely peak current, pulse on time, pulse off time and gap voltage have been considered for TWR investigation. Individual and interactive influence of various parameters on TWR is explained with the help of analysis of variance and three dimensional graphs. Using RSM approach, results have been further optimized. PMEDM approach provides 51.12% reduction in tool wear rate for machining of AA6061/10%SiC p composite.

Section: Conventional Edm Approach For Materialsmentioning

confidence: 99%

Section: Interactive Effects Of Process Parameters On Twrmentioning

confidence: 99%

Investigation of the Tool Wear Rate in Tungsten Powder-Mixed Electric Discharge Machining of AA6061/10%SiC_pComposite

Singh

Kumar

Kumar³

2015

Self Cite

“…Although extensive research work has been reported on EDM characteristics, it suffers from a few limitations such as low machining efficiency, tool electrode wear and over cut. To overcome these limitations, researchers [3][4][5][6][7][8][9][10] have conducted various studies. Rajurkar and Lin [11] have conducted an extensive review on machining of titanium alloy using EDM and related influencing factors.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti–6Al–4V

Kuriachen

Mathew

2014

Micro electric discharge milling is acquiring more importance in micro manufacturing because of its unique ability to produce three dimensional micro cavities with high aspect ratio in electrically conductive advanced materials regardless of its mechanical properties. The present study investigates the effects of major micro electric -discharge milling process variables (Voltage (V), Capacitance(C), electrode rotational speed (ERS) and feed rate (FR)) on Ti-6Al-4V. The output performance measures were identified as material removal rate (MRR) and tool wear rate (TWR) to assess the machinability of Ti-6AL-4V. Experiments were designed and carried out based on response surface methodology-Box Behnken statistical design. The most influencing parameters for responses (MRR, TWR) were found to be capacitance and feed rate. At a capacitance of 0.4 µF and feed rate of 18 mm/min, maximum MRR of 0.9756 mg/hr and TWR of 0.6342 mg/hr were observed. Similarly at 0.01 µF and 6mm/min, minimum MRR of 0.2308 mg/hr and TWR of 0.1259 mg/hr were obtained. Downloaded by [UNAM Ciudad Universitaria] at 20:25 25 December 2014 2

“…In order to prevent the formation of surface cracks, high roughness and thick recast layer during EDM, number of advancements in EDM process has been employed by many Downloaded by [George Mason University] at 06: 41 22 June 2016 researchers such as Ultrasonic Vibration Assisted EDM (UVAEDM) [20], Rotary Assisted EDM (RAEDM) [21], HyFlex EDM [22], Electro Discharge Coating/surface modification by composite or green tool electrode [23][24][25][26][27][28], Near Dry EDM [29] and Powder Mixed EDM (PMEDM) [30][31][32][33][34][35][36]. Among them, PMEDM has been considered the most promising approach to enhance the surface quality by reducing surface crack density [37].…”

mentioning

confidence: 99%

Experimental investigations in powder mixed electric discharge machining of Ti–35Nb–7Ta–5Zrβ-titanium alloy

Prakash

Kansal

Pabla

et al. 2016

182

The present research is the first type of study, in which the application of powder mixed electrical discharge machining (PM-EDM) for the machining of β-phase titanium (β-Ti) alloy has been proposed. β-Ti alloys are new range of titanium alloys, which has wide spread application in dental, orthopaedics, shape memory, and stents. The aim of the present study is to fabricate submicro-and nano scale topography by PMEDM process to enhance the biocompatibility without affecting machining efficiency. The effect of Si powder concentration along with pulse-current and duration on the surface and machining characteristics has been investigated. A significant decrease in surface crack density on the machined surface with 4 g/l Si powder concentration was observed. When β-Ti alloy was modified at 15 A pulse-current, longer pulse interval with 8 g/l concentration of Si powder particles, the interconnected surface porosities with pore size 200-500 nm was observed. Moreover, at Si powder concentration of 2 and 4 g/l, the recast layer thickness is 8µm and 2-3 µm, respectively. Elemental mapping analysis confirmed that PMEDM also generated carbides and oxides enriched surface, a favourable surface chemistry to enhance the biocompatibility of β-Ti alloy. Furthermore, Downloaded by [George Mason University] at 06:41 22 June 2016 2 PMEDM also enhances the machining performance by improving MRR and reducing TWR.