Informatics Publishing Limited

B. Kishan ¹, B. Sudheer Prem Kumar ¹, S. Gajanana ², B. Ravi Kumar ², P. V. K. Chaitanya Kumar ²

Affiliations
1 Department of Mechanical Engineering, JNTUH College of Engineering, Hyderabad, Kukatpally, IN
2 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN

Abstract

Electrical Discharge Machining (EDM) is one of the electrical energy based Modern Machining Technique. where electrical energy is directly used to remove or cut the metals. In the present work experiments are conducted on EDM using Al6061+SiC(3%,6%,9%), Copper and Brass materials as electrodes and EN8 steel as work material. Discharge current (I_P), pulse on time (T_ON), pulse off time (T_OFF) are selected as process parameters, Surface Roughness (S_R), Tool Wear Rate (TWR) as response. Taguchi design of experiment is used to find the influence of process parameters on response and a mathematical model is developed. Percentage contribution of each factor is determined.

Keywords

Discharge Current(I_P), Pulse on Time (T_ON), Pulse Off Time (T_OFF), Surface Roughness, EDM.

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B. Ravi Kumar ¹, S. Gajanana ¹, Hemachandra Reddy ², P. V. K. Chaitanya Kumar ¹, A. Teja Vardhan ¹

Affiliations
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Andhra Pradesh State Council of Higher Education (APSCHE), Andhra Pradesh, IN

Abstract

Flow forming is an advanced, near net shape, chip less metal forming process, which employs an increment rotary point deformation technique for manufacturing seamless symmetrical products. Spinning is an advanced continuous and localized metal forming process, which is widely used in many fields due to its advantages of flexibility, high quality and low cost. It is frequently used for manufacturing axisymmetric shapes where press tooling might not be justified on grounds of size and production volumes. It is characteristic of this process that the deformation does not occur in an annular zone around the axis of rotation but that the tools act upon a much localized area in which plastic flow takes place. During spinning tools are moved relative to the rotating work piece. In this paper, a regression model showing the relation among input process parameters, Mandrel speed (rpm), Roller type and Thickness of sheet (mm) and output (response) as surface roughness (μm) is developed using Minitab Software. The experiments were conducted on Aluminium 2024 T-3 sheets with cylindrical mandrel using Taguchi orthogonal arrays (L9). Further Analysis of Variance was carried out to find the contribution of each parameter on the surface roughness.

Keywords

Mandrel Speed (rpm), Thickness of Sheet (mm), Surface Roughness (μm).

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B. Ravi Kumar ¹, S. Gajanana ¹, K. Hemachandra Reddy ², P. V. K. Chaitanya Kumar ¹

Affiliations
1 MVSR Engineering College, Hyderabad, Andhra Pradesh, IN
2 AP State Council for Higher Education, Vijayawada, Andhra Pradesh, IN

Abstract

Spinning is widely used metal forming process to fabricate components or products have rotational symmetry. It is a localized metal forming process which is mainly used due to its advantage of high quality associated with low cost for manufacture. In this process a tool is pressed against the rotating pre form of final product. The surface rough ness is one of the important parameters of spun product which are used in aerospace industry. In the present study an investigation is carried out on Al2024 material to get a conical product by adopting Taguchi OA methodology for experimentation. The experiment is carried out by using two different geometry rollers namely single roller and double radii roller at two different rotational speeds on different thickness of sheets as input parameters. The surface roughness is the target response in this investigation. Regression model for surface roughness is developed using MiniTAB software. Further Analysis of Variance was carried out to find the contribution of each parameter on the response.

Keywords

Conical Mandrel, Surface Roughness, Regression Model, Taguchi Method.

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