Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining - PDF

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Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Amoljit Singh Gill 1 and Sanjeev Kumar 2 1,2 Mechanical Engineering Dept., PEC University of Technology, Chandigarh
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Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Amoljit Singh Gill 1 and Sanjeev Kumar 2 1,2 Mechanical Engineering Dept., PEC University of Technology, Chandigarh , India Abstract C and below, to cause beneficial changes in the material properties. It makes the crystal more perfect, stronger, relieves residual stresses, and improves electrical properties. Electro discharge machining (EDM) is a well known non-traditional machining process, which converts electrical energy to thermal energy and removes material by melting and evaporation from electrically conductive materials. In this process the dimensional stability and machined surface characteristics depends greatly on electrode wear. In this research work, the effect of cryogenic treatment on the wear of tool electrode is experimentally investigated using Taguchi design approach. The study has been carried out on hot die steel (AISI H11) using Aluminium as tool material. Experiments were conducted to study the effect of various process parameters. The results of study suggest that deep cryogenic treatment significantly reduces electrode wear. Keywords: Electrical discharge machining; Aluminium tool electrode; Deep cryogenic treatment; Tool wear; AISI H11 hot die steel. INTRODUCTION MRR and SR [10, 11]. cryogeni temperature [12]. and grain boundary realignment occurring in the material. International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN: Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Singh and Kumar EXPERIMENTATION treated aluminium and non cryogenic treated aluminium Table 1: Levels of Input Machining Parameters Parameter L1 L2 L T on (μsec) V (V) RESULTS AND DISCUSSION E aluminium electrode and cryogenic treated aluminium Experiment Table 2: Orthogonal Array L9 Matrix Current (Amps) A On Time (μsec) B Duty Factor (%) C Voltage (V) D Where, y j 20 International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN: Singh and Kumar Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Where Results with Non Cryogenic Aluminium Electrode Table 3: Observed Values of TW (Non Cryogenic Aluminium Electrode) Exp. TW (%) S/N Ratio No. Run 1 Run 2 Run and the experimental opt = ( ) + ( ) + ( ) + ( ) = opt = experiment (a) (b) (c) (d) Fig. 1: Effect of Various Parameters on Average Values of TW and S/N Ratio (Non Cryogenic Treated Aluminium Electrode) International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN: Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Singh and Kumar Fig. 2: SEM Micrograph after Machining with Non-Cryogenic Treated Aluminium Electrode at 1000x (Peak Current = 10 A, Pulse On-time = 150 μs, Duty Factor = 80%, Gap Voltage = 40 V) Results with Cryogenic Treated Aluminium Electrode [Fig. 3 (c)]. Table 4: Observed values of TW (Cryogenic Aluminium Electrode) Exp. No. TW (%) S/N Ratio Run 1 Run 2 Run Fr input opt = ( ) + ( ) + ( ) + ( ) = (a) (b) (c) (d) Fig. 3: Effect of Various Parameters on Average Values of TW and S/N Ratio. (Cryogenic Treated Aluminium Electrode) 22 International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN: Singh and Kumar Wear Reduction of Aluminium Electrode by Cryogenic Treatment in Electrical Discharge Machining Fig. 4: SEM Micrograph after Machining with Cryogenic Treated Aluminium Electrode at 1000x (Peak current = 5 A, Pulse On-time = 150 μs, Duty Factor = 80%, Gap Voltage = 40 V) Table 5: Comparison of Tool Wear and Optimal Combination of Factors Electrode Material Aluminium CONCLUSION Type of Electrode Tool Wear (%) Optimum Combination of Factors Non Cryogenic A 2 Treated Cryogenic Treated A 1 EDM u reported. 3. cryogenic treatment. 4. can be recommended that EDM tool ele 5. REFERENCES [1] Journal Mater. Process Technology, Vol , pp [2] Int. Journal machine Tools & Manuf, Vol. 43, pp [3] Int Journal Mach Tools Manuf, Vol. 43, pp [4] Journal Mater Process Technol, Vol , pp [5] Fundamentals of Modern Manufacturing, 2 nd [6] Am Journal App. Sci., Vol. 2(6), pp [7] Ann. CIRP, Vol. 32 (1), pp [8] Ann. CIRP, Vol. 27 (1), 1978, pp [9] Journal Mater. Manuf. Processes, Vol. 16 (1), pp [10] Int. Journal Adv. Manuf. Technol, Vol. 16 (5), pp [11] Precision Eng.,Vol. 8 (3), pp [12] Open Mech. Eng. Journal, Vol. 2, pp [13] Eng. Mater., Vol. 86, pp [14] Journal Mater. Process. Technol, Vol. 118, pp [15] Int. Journal Mach. Tools Manuf, Vol. 33 (2), pp [16] Int. Journal Prod. Res., Vol. 41 (3), pp [17] Journal Mater. Process. Technol, Vol. 84, pp [18] Int. Journal Adv. Manuf. Technol, Vol. 19, pp [19] Taguchi Techniques for Quality Engineering, International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN:
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