TAGUCHI GREY RELATIONAL MULTI-RESPONSE EXPERIMENTAL OPTIMIZATION ON MODIFICATION OF Al-6061 SURFACE USING Si–Cu GREEN COMPACT TOOL IN EDM

Abstract

This paper presents the surface modification of aluminium-6061 by electric discharge machining (EDM). Si–Cu powder metallurgical green compact tool is used to deposit its material on to the work surface under reverse polarity of EDM. Compact load, current and pulse on-time are selected control parameters. Material deposition rate (MDR), tool wear rate (TWR) and surface roughness ([Formula: see text] are considered as process outputs. Scanning electron microscopic (SEM) analysis and energy dispersive X-ray (EDX) analysis show the presence of tool materials in the deposit of work surface. Olympus optical micrograph shows an average thickness of the deposited layer to be 18.73[Formula: see text][Formula: see text]m. The hardness of the deposited layer is found to be 268[Formula: see text]HV. Analysis of variance (ANOVA) shows the compact load to be the most effective parameter on surface modification followed by pulse on-time and current, respectively.

Surface modification in the shape of a pattern using crepe paper maskant in EDM

“…Material deposition is an important issue of the procedure. The rate of deposition increases with higher I p and longer T on , while it decreases with higher settings of CL [9]. Figure 4(a) reveals the variation of MDR in relation to CL, I p and T on settings.…”

“…Higher I p accelerates the tool erosion followed by high MDR. The T on regulates the MDR by controlling the discharge energy within a regulated period to erode the tool [9]. Shorter T on causes low MDR as a result of low rate of tool wear.…”

“…The surface modification requires a suitable amount of material deposition in relation to the roughness of the surface. With a decrease in I p , the rate of deposition reduces as CL increases, but increases as T on settings increase [9]. The MDR value is varied from 15.53 mg/min – 66.80 mg/min.…”

“…The change of its metallographic structure and the surface integrity are studied by them. Similarly, Mazarbhuiya et al [9] altered the aluminium-6061 work surface by PM tool of Si-Cu in EDM and observed changes to the surface properties. Similarly, Tyagi et al [10] altered the mild steel surface by mixing powders of hexagonal boron nitride with copper particles.…”

Surface modification of Al-7075 using Cu-CNT green tool in EDM

“…The work reports that higher I p leads to impairment of masking material which results in higher edge deviation (ED) and lower pulse on-time induces low Ra and low ED. Mazarbhuiya et al [9] developed a green compact of Cu-Si tool to modify the surface of Al-6061. The deposited layer thickness was determined to be 18.73 µm, with a micro hardness of 263 HV.…”