Abstract

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EXPERIMENTAL ANALYSIS ON NICKEL ALUMINIUM ALLOY BY ELECTRIC DISCHARGE MACHINE USING TAGUCHI MODEL

Nirvikar Sharan Mishra, Atul Kumar Tiwari


Advanced structural ceramics, such as Silicon Carbide (Sic), Silicon Nitride (Si3N4), Alumina (Al2O3) and Zirconia (ZrO2) are attractive materials for many applications ranging from aero engines to dental restoration and is possible due to high hardness and strength, wear resistance, resistance to chemical degradation and low density. Various applications of these ceramic materials demand shaping to a high degree of surface finish and dimensional accuracy. These materials difficult to machine because of high hardness and abrasive nature of reinforcing elements like alumina particles. In this study, homogenized (4%, 6%, and 8%) by weight of alumina aluminum metal matrix composite materials were fabricated and selected as work piece for experimental investigations of surface roughness and metal removal rate. Among the machining processes used for shaping advanced ceramics, grinding is the most widely used machining process as it gives reasonably good rate of material removal. However, the high cost of diamond grinding and difficulty in machining complex shapes and 3D surfaces have promoted research into alternative methods of ceramics machining like ultrasonic machining, abrasive water jet machining, electrical discharge machining and laser beam machining. Electrical-discharge machining (EDM) is an unconventional, non-contact type machining process where metal removal is based on thermal principles. In this process, the material removal mechanism is based on the conversion of electrical energy into thermal energy through a series of discrete electrical discharges that occur between the electrode and work piece immersed in an insulating dielectric liquid. The concentrated heat of spark generates a channel of plasma between the cathode and anode at a temperature in the range of 8000 to 12,000 °C, initializing a substantial amount of heating and melting of material at the surface of each pole. When the direct current supply is turned off and the potential reaches above the breakthrough voltage of dielectric, the plasma channel breaks down.