Papers by Keyword: Metal Removal Rate (MRR)

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Authors: S.K. Dinesh Kumar, R. Selvanayagam, M. Sivakumar, S. Krishnaraj
Abstract: Wire electrical discharge machine (WEDM) is extensively used in machining of conductive material where precision is of prime importance. Machining operation in WEDM is treated as a challenging one because improvement of more than one Machining performance characteristics are sought to obtain precision work. This project illustrates the implementation of Taguchi technique to select the best optimal machining parameters of WEDM process using Copper powders. In general the machining parameters namely metal removal rate and the surface roughness are determined in WEDM process. The machining material chosen for the experiment is HCHCr alloy steel. Experiments were conducted as per Taguchi’s L18 orthogonal array under different cutting conditions of pulse on-time, pulse off-time, current and frequency and the results are compared. The level of significance of the machining parameters on the output characteristics is identified by Analysis of Variance. Finally this research concludes that the copper powder suspended demineralized water when used as dielectric gives higher MRR and lower Ra. Taguchi optimization is carried out to find the best combination of machining parameters to obtain the desired result
Authors: K. Jayakumar
Abstract: Machining of Aluminum Metal Matrix Composites (AMMCs) is a challenge for manufacturing industries due to their heterogeneous constituents which vary from soft matrix to hard reinforcements and their interfaces. To overcome the difficulties in machining of MMCs, researchers are continuously working to find the optimum process or machining parameters. In this work, End milling studies were carried out in A356 alloy powder-SiC particles (1 μm) in 0, 5, 10, 15 volume % reinforced AMMCs synthesised by vacuum hot pressing (VHP) route.The influence of machining parameters such as cutting speed, feed and depth of cut on the prepared composites in terms of surface roughness (Ra) and material removal rate (MRR) are measured from experimental study. Experiments were conducted as per Taguchi L16 orthogonal array with 4 factors and 4 levels.From the experimental result, it was identified that surface roughness varied from 0.214 μm to 4.115 μm and MRR varied from minimum of 1.11 cm3/min to maximum of 9.65 cm3/min. It is also observed that, MRR increased with increase in machining parameters and reinforcement quantity. Similarly, surface roughness decreased for increase of cutting speed, SiC particle (SiCp) reinforcement and increased for increase in feed and depth of cut. The optimum condition were observed in higher speed, lower feed and higher depth of cut on MMC with higher SiC content (15%) for getting higher machinability.
Authors: Vasudevan Chandrasekaran, D. Kanagarajan, R. Karthikeyan
Abstract: Proper selection of manufacturing conditions is one of the most important aspects in the die sinking Electrical Discharge Machining (EDM) process, as these conditions determine important characteristics such as Material Removal Rate and Surface Roughness.In this work, mathematical models have been developed for relating the Material Removal Rate (MRR) and Surface Roughness (Ra), to machining parameters like tool rotational speed (S), discharge current (C), pulse-on time (T) and flushing pressure (P). The experiment plan adopts the centered central composite design unblocked (CCD). The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). This study highlights that the proposed mathematical models have proven to fit and predict values of performance characteristics close to those readings recorded experimentally with a 95% confidence interval. Results show that are the two significant factors affecting MRR (discharge current and flushing pressure). The discharge current, flushing pressure and electrode rotation have statistical significance on the Ra.
Authors: C. Nandakumar, B. Mohan, C. Senthilkumar, K. Vickram
Abstract: Wire-electro discharge machining (WEDM) is one of the important non-traditional machining processes used to machine difficult-to-machine materials and complicated profiles. Being a high degree of complexity process, it is unfavourable to determine optimal parameters for improving cutting performance. Metal removal rate and surface finish are most important response parameters, which decide the performance on cutting. The single optimal combination of cutting parameters is not there, as their influences on the metal removal rate and the surface finish are quite the opposite. In the present study, a multiple regression model is used to represent relationship between input and output variables and the parameters were optimized based on response surface metho dology (RSM).
Authors: B. Geetha, K. Ganesan
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.
Authors: Triyono, Dedi Priadi, Eddy S. Siradj, Winarto
Abstract: The emergence of white layer in each process of Electric Discharge Machining (EDM) becomes the focus of attention of the experts. It is harder than the base metal would be advantageous to withstand friction engine components, such as the plastic molding industry. From various studies it has been reported that the increase in the value of hardness of white layer either due to migration of the electrode material and dielectric fluid to the white layer. This paper discusses the influence of electrodes Cu, CuCr and graphite as well as jatrophacurcas dielectric fluid to the surface of the material SKD 61, microhardness of the white layer, Tool Wear Rate (TWR) of Material Removal Rate (MRR), Surface roughness (Ra) and the microstructure. Initial studies conducted are the transesterification and characterization of jatrophacurcas to determine the dielectric strength and the content of metal elements. Furthermore, the EDM testing is done to dies steel of SKD 61 using the electrodes of Cu, CuCr and Graphite. The use of jatrophacurcas yield the best MRR when using Graphite electrodes followed Cu last CuCr. While the smallest TWR produced by Cu electrode, CuCr and then the highest is Graphite. The relative wear which is the ratio TWR with MRR, for the three types of electrodes is always great at a small current then decreases and then tends to be stable with the increase of electric current. Jatrophacurcas for the three types of electrodes provide higher TWR than kerosene. This means that migration of materials is beneficial because larger material, but in terms of the geometric accuracy of the product can lead to decreasing of dimensional tolerances. Vickers hardness values of white layer is achieved by CuCr electrodes, Graphite lowest. Microstructural observation results of EDM white layer using graphite electrodes produce a more uniform thickness than the white layer using Cu and CuCr electrodes. The conclusion of this study that jatrophacurcas can be used as a dielectric fluid in EDM process, because electrode wear during EDM process is relatively high compared with kerosene that is mean more profitable in the surface treatment process of dies steel of SKD 61.
Authors: Gugulothu Bhiksha, K. Buschaiah
Abstract: In electro discharge machining (EDM) the metal removal occurs from the erosive effects of high frequency sparks. Consequently the erosion rate depends on spark energy sparking frequency and the factors affecting them. However the experimental results are highly random and sometimes unexpected. Material erosion rate and surface roughness were analysed for the effect of important factors like pulse parameters (voltage current, ontime and offtime), polarity and work material. Taguchi method of experiment planning with orthogonal arrays was adopted to analyse the anomalies observed in the experimental results.
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