Manufacturing Technology Today

M. R. Dhanvijay ¹, B. B. Ahuja ¹

Affiliations
1 Department of Production Engineering and Industrial Management, College of Engineering, Pune [COEP], Wellesley Road, Shivajinagar, Pune, Maharashtra, IN

Abstract

Electrochemical discharge machining is a non-conventional machining technique for machining electrically non-conducting materials like glass, quartz, ceramics, and composites. Spark generation and control of gas bubbles around the tool has been a major problem in many researches. This work aims towards possibility of improving the material removal rate (MRR) and reduction of diametric over cut (DOC) by adding graphite powder to the electrolyte. The most effective values for machining parameters have been analyzed using the Taguchi S/N ratio analysis. Maximum MRR is obtained at high level of applied voltage, duty factor and concentration of electrolyte and moderate level of concentration of powder. Similarly the minimum DOC is obtained at low level of applied voltage and duty factor and moderate level of concentration of electrolyte and concentration of graphite powder between 3- 4 wt%. Confirmation test with optimal level of process parameters is carried out to validate the obtained optimum value.

Keywords

ECDM, Powder-Mixed ECDM, Graphite Powder, Taguchi Analysis.

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Prashant A. Patil ¹, M. R. Dhanvijay ¹

Affiliations
1 Department of Production Engineering and Industrial Management, College of Engineering Pune, Pune, Maharashtra, IN

Abstract

Hard turning is becoming more popular for machining hardened steels as it has several benefits over grinding. It is defined as machining steel with hardness greater than 45 HRC. PCBN is the widely used tool material for hard turning applications due to its high hardness, high wear resistance, and high thermal stability. There are several issues, which should be understood and dealt with, to achieve successful performance of hard turning process. The objective of present work is to establish a correlation between cutting parameters such as cutting speed, feed rate and depth of cut with cutting force and surface roughness on work piece. Optimization of cutting parameters for minimising cutting forces and surface roughness while turning 42CrMoS4 steel of 55±2 HRC. It is observed that, the use of lower feed (0.05mm/rev), lower depth of cut (0.2mm) and limiting the cutting speed to medium value (180 m/min) ensures minimum cutting forces (100N to 150 N) and surface roughness (0.467 μ).

Keywords

Hard Turning, PCBN, Surface Roughness, Regression Analysis.

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