The Effect of EDM Die-Sinking Parameters on Machining Characteristics in Aluminum Alloy Machining

Abstract:

The effect of machining parameters on machining characteristics for aluminium alloy LM6 (Al-Sil2) in Electrical Discharge Machining (EDM) die-sinking is studied. The objective of this project is to determine the relationship between the machining parameters including pulse-on time, pulse-off time, peak current and voltage with the machining characterictics such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (Ra). Copper materials having diameter 15mm was chosen as the electrode tool. Design of experimenent using Taguchi technique was employed to design experimental matrix that was used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that current and pulse off time significantly affect MRR, EWR and Ra while pulse on time and voltage are less significant in their effect on machining responses. Results show that using Taguchi as a design matrix, the best setting of optimum value for machining parameters to find the required machining responses can be obtained.

• Periodical: Applied Mechanics and Materials (Volume 761)
• Pages: 303-307
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.761.303
• Online since: May 2015
• Authors: Laily Suraya*, Mohd Amran Ali, Nur Izan Syahriah Hussein, Mohd Razali Muhamad, Manshoor Bukhari, Mohd Amri Lajis, Izamshah Raja, Hadzley Mohd, Taufik Taufik
• Keywords: EDM Die-Sinking, Electrode Wear Rate, Material Removal Rate (MRR), Surface Roughness

References

[1] M.A. Abbas, G.S. Darius, M.F. 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

[2] 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, pp.3941-3950, Jun (2012).

DOI: 10.1016/j.proeng.2012.06.451

[3] 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

[4] J.P. Davim, Machining of Complex Sculptured Surfaces, Springer London, New York, (2012).

[5] E. Kannatey, J.R. Asibu, Principles of Laser Materials Processing, John Wiley & Sons, New Jersey, (2009).

[6] Y. Jamal, A. Sheikh, Machining of Polymer Matrix Composites, Springer, New York, (2009).

[7] R. Karthikeyan, P.R.L. Narayanan, R.S. Naagarazan, Mathematical modelling for electrical discharge machining of Aluminium-silicon carbide particulate composite, Mater. Proc. J. 87(1999) 59-63.

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

[8] A.A. Majdi, M. Alexis, A. Faiz, Non-conventional Machining of Aluminium Metal Matrix Composite, ICEEI Engineering and Informatics Conference, pp.5-7, Aug (2009).

[9] 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, Adv. Mater. Res. 903 (2014) 56-60.

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

[10] 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, Appl. Mech. Mater. 465-466 (2014).

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

[11] C. Velmurugan, R. Subramaniam, Experimental investigation on machining characteristic of Al 6061 hybrid metal matrix composite processed by electrical discharge machining, Int. J. of Eng. Sci. and Tech. 3(2012) 87-101.

DOI: 10.4314/ijest.v3i8.7

[12] Y. Guu, H. Hocheng, N. Tai, S. Liu, Effect of electrical discharge machining on the characteristic of carbon fiber reinforced carbon composites, Mater. Sci. 36 (2001) 2037-(2043).

[13] P. Janmanee, A. Muttamara, Performance of different electrode materials in electrical discharge machining of tungsten carbide, Energy Res. J. 1(2) (2010) 87-90.

DOI: 10.3844/erjsp.2010.87.90

[14] A.N. Kumar, V. Babu, C.K. Ambilikumar, Electro discharge machining of aluminium alloy (LM6)-5wt. % SiCp composites using copper electrode, Int. J. Emerg. Tech. Adv. Eng. 3(7) (2013) 2250-2459.

[15] K.M. Patel, P.M. Pandey, P.V. Rao. Optimization of process parameters for multi-performance characteristics in EDM of Al2O3 ceramic composite, Int. J. Manuf. Tech. 47 (2010) 1137-1147.

DOI: 10.1007/s00170-009-2249-7