Influence of Rotary Assisted Electrical Discharge Machining of 17-4PH StainlessSteel Using Taguchi Technique

The current investigation has study the material removal rate, surface roughness and electrode wear rate in rotary toolassisted EDM of 17-4 PH stainless steel. 17-4 PH SS has widely used in aerospace, marine, nuclear, and chemicalprocessing due to their characteristic high strength to weight ratio and corrosion resistance properties. This paper primarilyfocuses on enhancing the flushing efficiency of dielectric fluid in the EDM process and to improve the machiningperformance characteristics. A custom designed rotating electrode attachment has fabricated and used to assist with theEDM process. The experiments are designed and planned using Taguchi L27 Orthogonal array technique.The experimentsare planned for four input factors and each parameter is varied at three levels. Current, pulse on time, pulse off time andElectrode Rotation Speed are input factors. ANOVA test is conducted to find out the significance of factors and theirpercentage contribution on the performance characteristics like Material Removal Rate, Surface Roughness and ElectrodeWear Rate. The resultsconcluded that Electrode Rotation Speed has more influence on Material Removal Rate and ElectrodeWear Rate. An individual percentage and interaction percentage of parameters from ANOVA confirm that their effectsare higher in Material Removal Rate (MRR) compared to Surface roughness (Ra) and Electrode Wear Rate (EWR). Finally,surface morphology studies revealed that significantly less cracks and voids had formed on the EDM’ed sample at optimumcondition

Effect of dielectric fluid with surfactant and graphite powder on Electrical Discharge Machining of titanium alloy using Taguchi method

In this paper, Taguchi method was employed to optimize the surfactant and graphite powder concentration in dielectric fluid for the machining of Ti-6Al-4V using Electrical Discharge Machining (EDM). The process parameters such as discharge current, surfactant concentration and powder concentration were changed to explore their effects on Material Removal Rate (MRR), Surface Roughness (SR), Tool wear rate (TWR) and Recast Layer Thickness (RLT). Detailed analysis of structural features of machined surface was carried out using Scanning Electron Microscope (SEM) to observe the influence of surfactant and graphite powder on the machining process. It was observed from the experimental results that the graphite powder and surfactant added dielectric fluid significantly improved the MRR, reduces the SR, TWR and RLT at various conditions. Analysis of Variance (ANOVA) and F-test of experimental data values related to the important process parameters of EDM revealed that discharge current and surfactant concentration has more percentage of contribution on the MRR and TWR whereas the SR, and RLT were found to be affected greatly by the discharge current and graphite powder concentration

Influence of Rotary Assisted Electrical Discharge Machining of 17-4PH Stainless Steel Using Taguchi Technique

801-808The current investigation has study the material removal rate, surface roughness and electrode wear rate in rotary tool assisted EDM of 17-4 PH stainless steel. 17-4 PH SS has widely used in aerospace, marine, nuclear, and chemical processing due to their characteristic high strength to weight ratio and corrosion resistance properties. This paper primarily focuses on enhancing the flushing efficiency of dielectric fluid in the EDM process and to improve the machining performance characteristics. A custom designed rotating electrode attachment has fabricated and used to assist with the EDM process. The experiments are designed and planned using Taguchi L27 Orthogonal array technique.The experiments are planned for four input factors and each parameter is varied at three levels. Current, pulse on time, pulse off time and Electrode Rotation Speed are input factors. ANOVA test is conducted to find out the significance of factors and their percentage contribution on the performance characteristics like Material Removal Rate, Surface Roughness and Electrode Wear Rate. The resultsconcluded that Electrode Rotation Speed has more influence on Material Removal Rate and Electrode Wear Rate. An individual percentage and interaction percentage of parameters from ANOVA confirm that their effects are higher in Material Removal Rate (MRR) compared to Surface roughness (Ra) and Electrode Wear Rate (EWR). Finally, surface morphology studies revealed that significantly less cracks and voids had formed on the EDM’ed sample at optimum condition

MULTI RESPONSE OPTIMIZATION OF EDM PROCESS PARAMETERS FOR INCONEL X-750 USING MOORA

Electrical discharge machining (EDM) is used extensively to machine hard to cut materials like nickel, titanium and super alloys with higher dimensional accuracy and surface finish. In this present study, a multi response optimization on the basis of ratio analysis (MOORA) is proposed for finding optimum process parameter of Electrical Discharge machining (EDM) during machining of Inconel X-750 material which is used mostly in thermal erosion process like nuclear plants, aerospace industry. In this study, response surface methodology (RSM) with Box-Behnken approach has been utilized for selecting the appropriate process parameters by using three level four factor (discharge current (Ip), voltage (V), pulse on time (Ton) and pulse off time (Toff)) using tungsten copper electrode (W-Cu). The machining responses considered are material removal rate (MRR), surface roughness (SR) and tool wear rate (TWR). The satisfactoriness of developed mathematical model has been tested with the use of analysis of variance (ANOVA). Further mathematical equations are generated using the statistical software MINITAB 17. The experimental data used for adequate regression model to optimize the process using MOORA. Further the surface characteristics of the machined surface are identified using scanning electron microscope (SEM) and elements with their peak values are revealed with EDX analysis

Electrical Discharge Machining of SiC Reinforced 6061-T6 Aluminum Alloy Surface Composite Fabricated by Friction Stir Processing

Engineered materials with high hardness, great wear tolerance, high high-temperature power, and a low thermal expansion coefficient are aluminum-based composites. These materials are widely used in the automotive and aerospace industries. Friction stir processing (FSP) method used to prepare SiC reinforced aluminium alloy surface composite. Material removal rate (MRR) and surface roughness (SR) are measured with the impact of pulse on time, discharge current, and pulse off time (add one or two outcomes remark at SR and MRR optimal condition) is examined. For each of the three machining parameters, L9 orthogonal arrays (OA) of three levels were used in conducting the experiments. The validity of the Aluminum Surface Composite experiment programme is determined using MINITAB

Effects Of Submerged Friction Stir Welding On Mechanical Properties Of AA6061 In Seawater

In this study, Al-Mg-Si alloy AA6061-T6 plates were joined in a seawater environment using the Submerged Friction Stir Welding (SFSW) technique, and process parameters were optimized using Taguchi L9 orthogonal arrays (OA). The parameters considered were tool rotational speed, tool transverse speed, and tool pin geometry. The MINITAB-17 software was used to analyze the responses using the signal-to-noise (S/N) ratio and analysis of variance (ANOVA). The optimum process parameters for tensile strength and joint Microhardness were determined. Furthermore, the ANOVA reveals that the tool rotational speed is the most important factor in determining joint mechanical properties such as UTS and Microhardness, with transverse speed and tool pin geometries coming in second and third. Experimental results confirm the effectiveness of this approach. The parent material microstructure and submerged stir welded samples were compared using metallographic scanning electron microscopy (SEM)

Optimization of process variables on Electrical Discharge Machining of novel Al7010/B

In this paper, determination of optimum EDM input variables like discharge current (DC), pulse on time (Pon), pulse off time (Poff), and gap voltage (GV) on responses like material removal rate (MRR) and surface roughness (SR) using Taguchi technique on the novel Al7010/2%B4C/2%BN hybrid metal matrix nanocomposite (HMMNC) manufactured through ultrasonic assisted stir casting (UASC) route. The various experiments were planned and carried out L16 orthogonal array and regression equations were established by using Analysis of variance (ANOVA) to examine the impact of pulse factors. The outcomes exposed that discharge current greatest effect factor on MRR and SR was found with % contribution of 82.07% and 86.86%. It is also identified that the optimum level conditions of pulse factors for MRR and SR is A4B4C1D1 and A1B1C4D4. The outcomes were further determined by utilizing confirmatory experiment. The machined surface morphology was observed through Scanning electron microscope (SEM)

Evaluation of Tensile Properties Using Uni-Axial Testing and Correlation with Microstructure of AA2014 alloy

AA2014 is most widely used metal among the aluminium alloy series due to its exceptional corrosion resistance, low density rate, and it can maintain high strength and toughness at various temperatures. So, these materials have their application in the aerospace, military and the automotive sector. The present work focuses on evaluating the mechanical properties such as ultimate Tensile strength (UTS), Yield strength (YS), and percentage of elongation using Uniaxial Tensile test. The three controllable factors used in the present study are temperature ranging from 200 to 300°C with 50°C increment, orientation 0,45,90 degree relative to the rolling direction and strain rate 0.001,0.01 and 0.1mm/sec. A total of 27 experiments were planned and conducted based on the design of experiments. Experimental results show that with increase in strain rate increasing of material properties furthermore with increase in temperature decrease of material properties and increase in the percentage of elongation was observed. In addition to that ANOVA analysis was carried out and noticed that strain rate is most effecting parameter for UTS and temperature is most effecting parameter for YS and percentage elongation. The fracture specimens from uniaxial test are investigated for type of fracture through microstructural studie

Tensile And Formability Studies on AISI310 Austenitic Stainless Steel

Stainless steel is an alloy of iron, chromium, and, occasionally, nickel and other metals that resists corrosion. Metal is made into thin, flat pieces through an industrial process called sheet metal. One of the fundamental shapes used in metalworking, it can be cut and bent into many other shapes. Metal sheet is used to create a vast array of common items. The aim of the current work is to examine the 310 austenitic stainless steel’s formability at room temperature with different strain rates (i.e 0.1&0.01mm/s). The study’s outcomes were achieved through the utilization of the Nakazima test during stretch forming. Before performing formability test, The mechanical properties of a high-strength stainless steel AISI 310 were examined by conducting tensile tests at room temperature with 0.1,0.01mm/s strain rates. The failure modes, stress-strain curves of all the test specimens were obtained and analyzed. In the current experiment, the stretch forming of different shaped metal was tested in servo electric hot forming machine with different strain rates i.e, (0.1,0.01) at room temperature and plotted forming limit diagrams based on the results. Then simulations of the experiments were performed in LS-dyna software and compared with the practical experiment results