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SHRI MATA VAISHNO
DEVI UNIVERSITYKATRA (J&K)
VINEET DUBEYM.Tech Student
School of Mechanical
EngineeringICARI
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An Experimental Study On
Electro-dischargeachining o! Al201"#Al2O$
Composite
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Aluminium Metal Matrix
Como!ite!"MMC!#
• Metal matrix como!ite are como!ite material! $ith at lea!t
t$o con!tituent art!. %ne &eing a metal and the othermaterial ma' &e a di(erent metal or another material) !ucha! ceramic or organic comound.
• The!e are made &' di!er!ing a reinforcing material into ametal matrix . The reinforcement in AMMC! can &e in form of
continuou!*di!continuou! +&re!) $hi!,er! or articulate!.
• -roertie! of MMC! can &e tailored to the demand! of
di(erent indu!trial alication! &' !uita&le com&ination! ofmatrix) reinforcement! and roce!!ing route!.
• The reinforcement! !hould &e !ta&le in the gien $or,ingtemerature and non reactie too.
• The mo!t commonl' u!ed reinforcement! are Silicon Car&ide"SiC# and Aluminium %xide "Al/%0#.
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• Aluminium metal matrix como!ite are imortantengineering material for their roert' adantage
comared to monolithic metal! .
• MMC! roide u! the oortunit' to com&ine ariou!roertie! coming from ceramic and metal! includinghigher !ti(ne!!) &etter $ear re!i!tance) increa!ed !eci+c!trength and !uerior roertie! at eleated temerature!)into one material.
• The!e material! are utili!ed in high1tech !tructural andfunctional alication! including aero!ace) defence)automotie a! $ell a! in !ort! and recreation.
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2imitation! In Deeloment %f
Aluminium MMC!
• Metal matrix como!ite! hae roed to &edi3cult to machine u!ing conentionaltechni4ue!) due to high tool $ear rate cau!ed&' the re!ence of hard reinforcement.
• 5ence non1traditional machining roce!!e!o!e a !olution for machining of !uchcomo!ite!.
•
Among them) EDM i! one of the mo!t oularnon1traditional roce!! u!ed for machiningelectricall' conductie $or, materialregardle!! of it! hardne!!.
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Electric Di!chargeMachining"EDM#
•In 6780 Soiet !cienti!t 2a9aren,o &rother! had exloited the de!tructiee(ect of electrical di!charge! and deeloed a controlled roce!! formachining material! that are conductor! of electricit'.
•EDM i! a thermal roce!! $hich ma,e! u!e of !ar, di!charge! to erodethe material from $or,iece !urface. The cait' formed in EDM i! arelica of the tool !hae u!ed .
•In die 1 !in,er EDM $or,iece and tool are !u&merged into a nonconducting) dielectric :uid $hich i! !earated &' a !mall ga"for!ar,ing#.
• The dielectric hel in cooling do$n tool and $or,iece) clear! the interelectrode ga "IE;# and concentrate the !ar, energ' to a !mall cro!!!ectional area under the electrode.
• The main comonent of Die Sin,er EDM are <
-o$er Sul'
Dielectric !'!tem
Electrode!
Sero !'!tem ICARI
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Die1Sin,ing EDM
Schematic of Electric Di!charge
Machining ICARI
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-a!t =e!earch >or, in EDM of MMC!
U!e of di(erent reinforcementmaterial a!<
Silicon car&ide "SiC#
Aluminium %xide "Al/%0#
Boron car&ide "B8C#
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-a!t =e!earch >or, in EDM of MMC!
U!e of di(erent otimi!ationtechni4ue! a!<
;re' =elational Anal'!i! ";=A#
=e!on!e Surface Methodolog'"=SM#
Taguchi?! Method
2exicograhic goal rogramming)
etc. ICARI
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-a!t =e!earch >or, in EDM of MMC!
Di(erent erformance mea!ure!anal'!ed are<
Material remoal rate "M==#
Tool $ear rate "T>=#
Surface roughne!! "S=#
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Chemical como!ition of AA/68
allo' in $t
Alloy AA201"Coer 0.71.
Silicon .1.
Magne!ium .01.
Iron .
Finc ./
Titanium .6Mangane!e .81.6/
Chromium .6
Aluminium 7.817.
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Machining arameter! and their
leel!
%actors#le&els
-2 -1 0 1 2
A'Current
(A)
0 G 7 6/ 6
*' +ulseon time
(,s)
0 G 7 6/ 6
C' +ulse
otime(,s)
G 68 6/ /
.' /apoltage
()
0 8 G
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.esign layout ith actual parameters and experimental results o! RRand SR
Std
Order
Random
Order
Current
(A)
+ulse On
ime(,s)
+ulse O
ime(,s)
/ap
oltage()
RR
(g#min)
SR
(,m)
3 6 G 6/ 6/ 8 ./ 8./0
$ / G 6/ G 8 .08 .8
24 0 7 7 68 . 8.//
1 8 G G G 8 .00 8.
23 7 7 68 .6G G.787
6 G 6/ G 6/ 8 . 7.88
2 6/ G G 8 .68 .07
4 G G G G .0/8 G.67
5 7 6/ 6/ 6/ 8 .6/G .8
2$ 6 7 7 68 0 .6/6 .088
12 66 6/ 6/ G G .80G .068
1$ 6/ G G 6/ G .07 .70
60 G G 6/ 8 .77 8.0G/
13 68 0 7 68 .G 8.7
14 6 7 0 68 .60 .G0
21 6G 7 7 .88G .G7/
20 6 7 6 68 .66G .70G
15 6 6 7 68 .67G .0G
1 67 G 6/ 6/ G .00G G./G77
$0 / 7 7 68 .GG 0.0
25 /6 7 7 68 ./86 8.7/
2 // 7 7 68 .67 .G8
" /0 6/ 6/ G 8 .07// 6/.0
26 /8 7 7 68 .7G G.6GG
1" / 6/ G 6/ G .0G .
10 /G 6/ G G G .78 .8G
16 / 6/ 6/ 6/ G .666G 8.G
11 / G 6/ G G .G70 .G
2" /7 7 7 68 .G G.06
22 0 7 7 / .8/ G.7
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Machined >or,iece
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Coer Electrode
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EDM Setu
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Normal lot for re!idual! for M== H S=
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T$o factor interactie e(ect $ith S=
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Conclu!ion
• The roce!! ha! &een !ucce!!full' modelled u!ing =SM aroach. The !econd1order re!on!e model! hae &een alidated $ithanal'!i! of ariance. The relation &et$een roce!! arameter!and M== i! o&tained $ith regre!!ion modelling.
• 5igher M== can &e achieed at higher !etting of current) ul!e on
time and otimum !etting of ul!e o( time.• Current) ul!e on time and ga oltage are !igni+cant factor!
a(ecting !urface roughne!!.
• -roce!!e! arameter! are otimi9ed to get &e!t com&ination ofM== and S=. %timi9ation of the roce!! enhanced the M== and
reduced S= a! o&tained from con+rmator' exeriment.• Thi! !tud' can hel re!earcher! and indu!trie! for deeloing
relia&le ,no$ledge &a!e and earl' rediction of M== and S= $ithEDM roce!! for Al /68*Al/%0 como!ite.
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7A89
:O;
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