Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

Abstract:

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

• Periodical: Advanced Materials Research (Volumes 941-944)
• Pages: 1973-1976
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.941-944.1973
• Online since: June 2014
• Authors: B. Geetha*, K. Ganesan
• Keywords: Al7Si4Mg, Electric Discharge Machine, Metal Removal Rate (MRR), Red Mud, Taguchi Design

References

[1] Howell G. J and Ball A Dry sliding wear of Particulate – reinforced Aluminium Alloys against Automobile Friction Materials, Wear, Vol. 181-183(1995), pp.379-390.

DOI: 10.1016/0043-1648(95)90045-4

[2] Rawal S Metal Matrix Composites for space application, JOM, Vol 53, No4, (2001) pp.14-17.

[3] Benardos P. G and Vosniakos G. C Predicting surface roughness in machining : a review', International Journal of Machine Tools and Manufacture, Vol. 43 (2003) Issue 8, pp: 833-844.

DOI: 10.1016/s0890-6955(03)00059-2

[4] Teti. R Machining of composite materials, CIRP Annals-Manufacturing technology, Vol. 51 (2002), Issue 2 pp: 611-634.

DOI: 10.1016/s0007-8506(07)61703-x

[5] Pandy P. C Modern Mechanical Process, TMH , New Delhi, (1980).

[6] Dvivedi, A., Kumar, P. and Singh, I. Experimental investi. and optimization in EDM of Al 6063 Sic metal matrix composite, Inter.J. of Mach. andMachineof Mats, Vol. 3(2008), p.293–308.

[7] Venkat Prasat, Subramanian R., Praveen N., Arun L., Electric Discharge Machining of AlSi10Mg/Fly Ash/Graphite Hybrid Metal Matrix Composites, European Journal of Scientific Research, Vol. 59No. 4(2011) pp.485-498.

DOI: 10.1108/ilt-05-2011-0031

[8] Jose Duarte Marafona and Arlindo Araujo, Influence of work piece hardness on EDM performance, International Journal of Machine Tool Manufacturing Vol. 49 (2009), p.744–748.