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SHRI MATA VAISHNO

DEVI UNIVERSITYKATRA (J&K)

VINEET DUBEYM.Tech Student

School of Mechanical

EngineeringICARI


2/22

An Experimental Study On

Electro-dischargeachining o! Al201"#Al2O$

Composite

ICARI


3/22

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#.

ICARI


4/22

• 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.

ICARI


5/22

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!!.

ICARI


6/22

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


7/22

Die1Sin,ing EDM

Schematic of Electric Di!charge

Machining ICARI


8/22

-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#

ICARI


9/22


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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Di(erent erformance mea!ure!anal'!ed are<

Material remoal rate "M==#

Tool $ear rate "T>=#

Surface roughne!! "S=#

ICARI


12/22

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.

ICARI


13/22

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

ICARI


14/22

.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

ICA=I /6G


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Machined >or,iece

ICARI


16/22

Coer Electrode

ICARI


17/22

EDM Setu

ICARI


18/22

Normal lot for re!idual! for M== H S=

ICA=I /6G


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T$o factor interactie e(ect $ith S=

ICA=I /6G


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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.

ICA=I /6G


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7A89

:O;

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