Manufacturing Technology Today

H. S. Payal ¹, Rajesh Choudhary ², B. L. Sethi ³

Affiliations
1 Beant College of Engg. and Technology, Gurdaspur, Punjab, IN
2 Malout Institute of Management and Information Technology, Malout, Punjab, IN
3 M M College of Engg. and Technology, Mullana, Haryana, IN

Abstract

Electrical Discharge Machining (EDM), as a production process, has influenced its existence in variety of fields and industries during the recent years. Other than tool & die making, it has occupied the area of production of parts in aerospace, medical, optical, automotive, gauge making templates, standards, electronics, cutting tools, ceramics, composites and nuclear industries, working on and almost all advance materials. The most important performance measure in EDM is the Surface Roughness (SR); among other measures Material Removal Rate (MRR) and Tool Wear Ratio (TWR) could be listed. In this study, experiments were performed to determine parameters effecting SR along with structural analysis of surfaces with respect to material removal parameters. Experimental work has been conducted on EN-31 tool steel with copper, brass and graphite as the tool electrodes with kerosene oil as dielectric fluid. The data compiled during the experimentation has been used to yield the responses in respect of MRR and SR. Further, the detailed analysis of structural features of machined surface has been done by using Scanning Electron Microscope (SEM) to understand the mode of Heat Affected Zone (HAZ). The present paper highlights a practical approach for full exploitation of EDM capabilities.

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H. S. Payal ¹, B. L. Sethi ², Gurdip Singh ³

Affiliations
1 Dept. of Mechanical and Production Engineering, Beant College of Engineering and Technology, Gurdaspur (Pb), IN
2 Dept. of Mechanical Engineering, Thapar Institute of Engineering and Technology, Patiala (Pb), IN
3 Malout Institute of Management and Information Technology, Malout (Pb), IN

Abstract

The superior mechanical and physical properties of Metal Matrix Composites (MMCs) make them very attractive for a variety of engineering applications, but machining of MMCs using conventional methods like turning, milling and grinding etc. is not proving much for their progress, it is therefore essential to analyze non-conventional methods for optimum machining of composites. Although Electrical Discharge Machining (EDM) is an important non-conventional process for machining hard materials, yet Its application for composites is relatively less explored. This paper presents some of the results obtained to date from an on going experimental investigations related to EDMIng of 6061 Al/Al₂O₃ composites. The objective was to find out the effect of EDM parameters viz, discharge current and gap voltage on the machining performance. The responses studies mainly MMR and S. R., and it was observed that the current is distinctly the most significant factor Influencing both the responses.

Keywords

EDM, MMCs, Material Removal Rate, and Surface Roughness.

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H. S. Payal ¹, B. L. Sethi ²

Affiliations
1 Dept. of Mech. and Prod. Engg., Beant College of Engg. & Tech., Gurdaspur, IN
2 Dept, of Mech. And Ind. Engg., Thapar Institute of Engg. & Tech., Patiala, IN

Abstract

The purpose of this paper is to provide an overview of a recent trend of machining the composites. Also outlines the scope and highlights the status of research across the world. Composites are advanced metals reinforced with continuous or discontinuous fibers, or whiskers, or particulate. The particulate-reinforced composites have been developed during 1980's with attention focused on Aluminium-based composites with SiC and AI₂O₃ particles. Composites have many advantages, like high strength, toughness, stiffness, lightweight, and high heat resistant, over the conventional materials. However, their utilization is still limited by the high manufacturing costs involved, mainly because of the difficulties in machining these materials. Non-conventional machining methods like Water Jet Machining (WJM), Abrasive Jet Machining (AJM) and Laser Beam Machining (LBM) etc. are used for such materials, but they also have problems. To minimize some of these difficulties, one of the thermal process names Electrical Discharge Machining (EDM) is being discussed for present study of machining of composites. A comprehensive review of literature available related to this process has also been reported.

Keywords

Composite Materials, Non-Conventional Machining, and EDM.

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