MACHINING OF INCONEL 600 THROUGH ROTATORY DISC ELECTRO DISCHARGE MACHINE

GUIDE : MR.ANAND PANDEY

PROJECT MEMBERS: ATUL KUMAR(2700140002) JITENDRA KUMAR SINGH(0600140050) KHILENDRA PAL SINGH(0600140052) RITESH KUMAR SINGH(0600140096)

INDEX Introduction Process DescriptionMaterial For Tool & its PropertyMaterial For Work Piece & its PropertyActual experimental set upDesigning of Experiment

Performing the Experiment Literature survey References

ELECTRO DISCHARGE MACHINING

Introduction Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining process, where electrical energy is used to generate electrical spark and material removal mainly occurs due to thermal energy of the spark.

TECHNIQUE USED IN MACHININGIn that Taguchi L18 method is used.Taguchi method is a scientifically disciplined mechanism for evaluating and implementing improvements in products, processes, materials, equipment, and facilities. These improvements are aimed at improving the desired characteristics and simultaneously reducing the number of defects by studying the key variables controlling the process and optimizing the procedures or design to yield the best results. The method is applicable over a wide range of engineering fields that include processes that manufacture raw materials, sub systems, products for professional and consumer markets. In fact, the method can be applied to any process be it engineering fabrication, computer-aided-design, banking and service sectors etc. Taguchi method is useful for 'tuning' a given process for 'best' results.

Every experimenter develops a nominal process/product that has the desired functionality as demanded by users. Beginning with these nominal processes, he wishes to optimize the processes/products by varying the control factors at his disposal, such that the results are reliable and repeatable (i.e. show less variations). In Taguchi Method, the word "optimization" implies "determination of BEST levels of control factors". In turn, the BEST levels of control factors are those that maximize the Signal-to-Noise ratios. The Signal-to-Noise ratios are log functions of desired output characteristics. The experiments, that are conducted to determine the BEST levels, are based on "Orthogonal Arrays", are balanced with respect to all control factors and yet are minimum in number. This in turn implies that the resources (materials and time) required for the experiments are also minimum.

StepsinTaguchiMethodology

Step-1: IDENTIFYTHEMAINFUNCTION, SIDEEFFECTS,ANDFAILUREMODE.

Step-2: IDENTIFYTHENOISEFACTORS, TESTINGCONDITIONS,AND QUALITY CHARACTERISTICS.

Step-3: IDENTIFYTHEOBJECTIVEFUNCTIONTO BEOPTIMIZED.

Step-4: IDENTIFYTHE CONTROLFACTORSANDTHEIRLEVELS.

Step-5: SELECTTHEORTHOGONALARRAYMATRIXEXPERIMENT.

Step-6: CONDUCTTHEMATRIX EXPERIMENT.

Step-7: ANALYZETHEDATA, PREDICTTHEOPTIMUMLEVELSAND PERFORMANCE.

Step-8: PERFORMTHEVERIFICATIONEXPERIMENT ANDPLANTHEFUTURE ACTION.

Process Parameters

The process parameters in EDM are mainly related to the waveform characteristics. Fig. shows a general waveform used in EDM.

CONTROL PARAMETER OF EDM tool thickness The gap voltage - Vg The maximum current - Io The pulse on time the duration for which the voltage pulse is applied - ton Powder type Si , SiC , Al

The pulse off time - toff The gap between the work piece and the tool spark gap - Rotational speed of disc (tool) The dielectric medium Concentration of powder

MATERIAL FOR WORK PIECE

We have selected INCONEL 600 as a work piece which have following properties:- Chemical name . Inconel 600 Thickness of workpiece 1 mm

Volume fraction . 60-70% Ni

MATERIAL FOR TOOL We have selected COPPER for tool material. Which have following properties:Thermal conductivity - 391W/m-K

Melting point - 1083C

Electrical resistivity 1.69 ohm-cm

Specific heat capacity 0.385 J/g-C

Cadmium -- 1 to 1.5%

ACTUAL EXPERIMENT SETUP

TOOL & WORK PIECE

INDUSTRY.

SHARMA INDUSTRIES RAMBAGH, AGRA(U.P.) PROFILE : 1. DIE MAKING 2.PLASTIC MOULDING 3. MACHINING

MACHINE SPECIFICATION

Make .. SparkonixValue Rs. 4,50,000.00Hourly rate Rs. 125.00Max piece weight . 300 kg Mean table traverse . 300*400(mm*mm)Resolution .. 0.0005 mmMax machining current . 30 ampereDielectric fluid KeroseneTank capacity .. 60 Lt.

PARAMETER SELECTED

PEAK CURRENT (Ig)GAP VOLTAGE (Vg)PULSE ON TIME (Ton)IDLE TIME (Toff)TOOL THICKNESSPOWDER TYPECONCENTRATION OF POWDERROTATIONAL SPEED OF DISC(TOOL)

SELECTION OF LEVEL VALUES

The level values of eight selected optimizing parameter are given in following table:-

Symbolsparameterslevel1 level2level3ATOOL THICKNES0.51.5-BPEAK CURRENT61218CPULSE DURATION579DIDLE TIME579ERPM80100120FPOWDER TYPESiSiCAlGPOWDER CONC.0.40.50.6HGAP VOLTAGE180200220

DESIGN OF EXPERIMENT We have designed the experiment by TAGUCHI METHOD called ORTHOGONAL ARRAY METHOD for EIGHTEEN EXPERIMENT with THREE LEVEL VALUES OF EIGHT FACTOR

S.NOABCDEFGH10.565580Si8018020.5677100SiC10020030.5699120Al12022040.51255100SiC12022050.51277120Al8018060.5129980Si10020070.5185780Al10022080.51879100Si12018090.51895120SiC80200

101.5659120SiC100180111.567580Al120200121.5697100Si80220131.51257120Si120200141.5127980SiC80220151.51295100Al100180161.51859100Al80200171.51875120Si100220181.5189780SiC120180

Observation Table FOR WORK PIECE MATERIAL --------------------- INCONEL 600 SIZE ----------------------------- 600mm300mm

S.NOBeforem/c(in gm)After m/c(in gm)139.3739.35239.3539.34339.3439.33439.3339.32

539.3239.31639.3139.30739.3039.29839.2939.28939.2839.271039.2739.251139.2539.221239.2239.191339.1939.171439.1739.161539.1639.141639.1439.101739.1039.081839.0839.05

Observation Table

FOR TOOL MATERIAL---------------------- COPPER THICKNESS ---------------------- 0.5mm & 1.5mm

S.NOBefore m/c(in gm)After m/c(in gm)15.755.7225.725.7135.715.6945.695.6855.685.6665.665.6575.655.5785.575.5695.565.54

1034.7134.701134.7034.691234.6934.681334.6834.661434.6634.651534.6534.641634.6434.631734.6334.621834.6234.61

REFERENCE SITES: These are sites from where various papers for study of PROCESS , PARAMETER OF PROCESS & THEIR EFFECT have been taken: 1.www.elsevier.com 2. www.springerlink.com 3. www.presumproject.ro 4. www.sciencedirect.com

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