The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminum Composite

Abstract:

The machining ability of Electrical Discharge Machining (EDM) die-sinking on material characteristics of LM6 (Al-Sil2) is studied. This is due to the machining process on sharp edge, pocket, deep slot and micro hole cannot be performed by milling and turning machine. The objective of this paper is to determine the relationship between the machining parameters such as pulse on time, pulse off time, peak current and voltage on material removal rate (MRR) that are electrode wear rate (EWR) and surface roughness (Ra). Graphite tool of diameter 15mm was chosen as an electrode. Taguchi method is used as analysis technique to develop experimental matrix that is used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that the current and pulse off time are significantly effected the MRR, EWR and Ra while pulse on time and voltage are less significant factors that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

• Periodical: Applied Mechanics and Materials (Volume 699)
• Pages: 26-31
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.699.26
• Online since: November 2014
• Authors: Mohd Amran Ali*, Laily Suraya, Nor Atiqah Jaffar Sidek, Nur Izan Syahriah Hussein, Mohd Razali Muhamad, Bukhari Manshoor, Mohd Amri Lajis, Raja Izamshah, Mohd Hadzley, Taufik Taufik
• Keywords: EDM Die-Sinking, Electrode Wear Rate, Material Removal Rate (MRR), Surface Roughness (SR)

References

[1] R. Rajesh, M.D. Anand, The optimization of the electro-discharge machining process using response surface methodology and genetic algorithms, International Conference on Modelling, Optimization and Computing. 38 (2012) 3941-3950.

DOI: 10.1016/j.proeng.2012.06.451

[2] S. Assarzadeh, M. Ghoreishi, Statistical modeling and optimization of process parameters in electro-discharge machining of cobalt-bonded tungsten carbide composite. The 17th CIRP Conference on Electro Physical and Chemical Machining (ISEM). 6 (2013).

DOI: 10.1016/j.procir.2013.03.099

[3] M.A. Abbas, G.S. Darius, Md. Fuad Bahari, A review on current research trends in electrical discharge machining (EDM), Int. J. Mach. Tools Manuf. 47 (2007) 1214-1228.

DOI: 10.1016/j.ijmachtools.2006.08.026

[4] K.H. Ho, S.T. Newman, State of the art electrical discharge machining (EDM), Int. J. Mach. Tools Manuf, 43 (2003) 1287-1300.

DOI: 10.1016/s0890-6955(03)00162-7

[5] J.P. Davim, Machining of complex sculptured surfaces, Springer London, New York, (2012).

[6] E. Kannatey, J.R. Asibu, Principles of laser materials processing, John Wiley & Sons, New Jersey, (2009).

[7] Y. Jamal, A. Sheikh, Machining of polymer matrix composites, Springer, New York, (2009).

[8] R. Karthikeyan, P.R.L. Narayanan, R.S. Naagarazan, Mathematical modelling for electrical discharge machining of Aluminium-silicon carbide particulate composite, Material Processing Journal. 87 (1999) 59-63.

DOI: 10.1016/s0924-0136(98)00332-x

[9] A.A. Majdi, M. Alexis, A. Faiz, Non-conventional machining of aluminium metal matrix composite, 17th International Conference on Composites/Nano Engineering (2009) 5-7.

[10] A. Curodeau, M. Richard, L. Frohn-Villeneuve, Molds surface finishing with new EDM process in air with thermoplastic composite electrodes, Material Processing Journal. 149 (2004). 278-283.

DOI: 10.1016/j.jmatprotec.2003.10.040

[11] K.L.S. Kumar, R. Sivasubramaniam, K. Kalaiselvan, Selection of optimum parameters in non conventional machining of metal matrix composite, Portugaliae Electrochimica Acta. 27 (2009) 477-486.

DOI: 10.4152/pea.200904477

[12] C. Velmurugan, R. Subramaniam, Experimental investigation on machining characteristic of Al 6061 hybrid metal matrix composite processed by electrical discharge machining, International Journal of Engineering, Science and Technology 3 (2012).

DOI: 10.4314/ijest.v3i8.7

[13] Y. Guu, H. Hocheng, N. Tai, S. Liu, Effect of electrical discharge machining on the characteristic of carbon fiber reinforced carbon composites, Material Science. 6 (2001) 2037-(2043).

[14] M. Amran, L. Suraya, N. Assyura, N.I.S. Hussein, M.R. Muhamad, M. Bukhari, L.M. Amri, The Effect of EDM Die-sinking Parameters on Non-conductive Materials, Advanced Materials Research. 903 (2014) 56-60.

DOI: 10.4028/www.scientific.net/amr.903.56

[15] M. Amran, L. Suraya, N.H.I. Kamarudin, N.I.S. Hussein, M.R. Muhamad, M. Bukhari, L.M. Amri, The Effect of EDM Die-sinking Parameters on Material Characteristic for Aluminium Composite Using Tungsten Copper Electrode, Applied Mechanics and Materials. 465-466 (2014).

DOI: 10.4028/www.scientific.net/amm.465-466.1214