Abstract
PERFORMANCE STUDY OF POWDER MIXED ELECTROCHEMICAL DISCHARGE MACHINING (PMECDM) OF CERAMIC MATERIAL
Nilesh Mahajan*, Rohit Jadhav and M. N. Mathapati
ABSTRACT
A new method has been investigated to improve Electro-Chemical Discharge Machining (ECDM) process by use of powder mixed electrolyte. In Electrical Discharge Machining (EDM) processes, which is thermal erosion machining process using spark energy similar to the ECDM, powder-mixed EDM (PM-EDM) fluids have been used to improve machining characteristics. It has been reported that the powder stabilizes discharge current as a result of discharge energy dispersion. Considering the similarity of the ECDM process compared to EDM where electrical sparks are utilized, powder-mixed electrolyte is introduced to create similar effects. This work aims to improve the MRR by adding SiC abrasive to the electrolyte. A mechanism that combines discharge, chemical etching and abrasive cutting is studied. The effects on diametric overcut (DOC) and material removal rate (MRR) are discussed. Experiments on PMECDM have been carried out according to designed experimental plan based on standard orthogonal array (L9) to identify the optimal parametric conditions of PMECDM process using taguchi method of parametric optimisation. Signal to Noise (S/N) ratio is used to measure the quality charactristics deviating from the desired values. Regression analysis is done to determine the best suited equation connecting response with input variables, such as applied voltage, duty factor, electrolyte concentration and SiC concentration in controlling the machining performance, such as material removal rate and diametric overcut of the ECDM process. The chrome alumina is used as workpiece material and aqueous NaOH in stagnant condition as electrolyte is used. SiC powder of 1200 mesh size (10-15?m) is mixed with electrolyte.
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