Informatics Publishing Limited

J. Jeykrishnan ¹, B. Vijaya Ramnath ¹, A. Jude Felix ², C. Rupan Pernesh ¹, S. Kalaiyarasan ¹

Affiliations
1 Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai - 600044, Tamil Nadu, IN
2 Department of Mechanical Engineering, Mar Ephraem College of Engg & Tech, Marthandam – 629171, Tamil Nadu, IN

Abstract

Objectives: To find the important parameters that affects the performance output (i.e.) to boost the Material Removal Rate (MRR) of the workpiece. Methods: Electro–Discharge Machining (EDM) is a thermal based machining process which is used to remove ‘hard to cut materials’ with complex shapes. The principle with the EDM or spark eroding machining is that the unwanted materials are removed with the repeated current discharges between cathode and the anode, separated by a dielectric fluid and is subjected to an electric voltage. Findings: This paper investigates in optimizing the process variables of EDM by employing a traditional technique. The parameters chosen for optimization are pulse on time, pulse off time followed by the current and L9 Orthogonal Array (OA) has been selected to examine the impact of the process variables on the performance i.e. on the material removal rate. The experimental trials have been done on AISI D2 die steel with positive polarity and brass has been chosen as an electrode material. Applications: Mainly, the EDM are employed to machine difficult to cut materials like nickel base super alloys, titanium etc.

Keywords

AISI D2 Die Steel, Design of Experiments (DOE), Electro-Discharge Machining, Material Removal Rate.

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J. Jeykrishnan ¹, B. Vijaya Ramnath ¹, G. Sureshrajan ², M. Siva Bharath ², X. Hervin Savariraj ², S. Akilesh ¹

Affiliations
1 Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai - 600044, Tamil Nadu, IN
2 Department of Mechanical Engineering, DMI College of Engineering, Chennai - 600123, Tamil Nadu, IN

Abstract

Objective: The objective of this paper is to find the optimal machining parameters of Die-Sinking Electro-Discharge Machining on Inconel 825 alloy with nickel coated copper electrode for improving the process response. Methods: The effects of different parameters were studied on the machining responses. The machining parameters considered for this work were applied current, pulse on time and pulse off time and their effect on surface roughness response was studied. Findings: Taguchi optimization technique was employed to find the effect of machining parameters on Electro-Discharge Machining process responses. Besides, analysis of variance statistical method has been employed to predict the importance of individual machining parameters in the responses. The result of this research reveals that the proper selection of the input variables plays an important role in die-sinking EDM process. Applications: Ni base alloys are widely used in aviation, ship building and defense industries because of their better properties such as good impact strength, high ultimate tensile strength, high yield strength, high resistance to corrosion, retaining the strength even at high temperatures and fatigue resistance.

Keywords

Analysis of Variance, Die-Sinking EDM, Surface Roughness, Taguchi.

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J. Jeykrishnan ¹, B. Vijaya Ramnath ¹, X. Hervin Savariraj ², R. David Prakash ², V. R. Dhinesh Rajan ², D. Dinesh Kumar ²

Affiliations
1 Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai, IN
2 Department of Mechanical Engineering, DMI College of Engineering, Chennai, IN

Abstract

Objectives: The scope of this work was to: 1. to fabricate Silicon Carbide (SiC) particle Metal Matrix Composites (MMC) by vortex method; 2. to investigate the effect of SiC particles on the tensile and impact behavior of SiC particle reinforced 6061 aluminum alloy composites. Recently, the material technology has seen many contemporary developments in the field of fabricating new materials which reinstates the current materials for different applications. Amidst these, the composite materials have an important aspect which is a combination of different materials possessing various physical and chemical properties. Methods: This Aluminum base metal Matrix Composite (AMC) has been manufactured by wrought aluminum alloy by varying the weight fractions of silicon carbide to compose five distinct forms of composites. Stir – casting has been chosen as the manufacturing technique, in this study. Findings: The manufactured composites were tested to determine their tensile and impact properties and the result proves that the sample with higher percentage of silicon carbide has better mechanical properties, comparably. Applications: This study essentially focuses on establishing AMC as they find applications on aerospace and automotive industries because of their admirable properties compared with the unreinforced alloys.

Keywords

Aluminum 6061, Mechanical Properties, Metal Matrix Composite, Silicon Carbide, Stir Casting.

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