Investigation of process parameters in powder mixed electro discharge machining of Aluminium Silicon alloy using Brass electrode

Abstract

In this experimental work, Electrical discharge machining (EDM) is done on Al-Si alloy. In newlinecurrent study, cylindrical brass tool electrode with diameter of 25 mm is used. Copper newlinepowder (40 and#956;m) was mixed into the dielectric. Design of experiment done by Taguchi newlinemethod, first having L9 orthogonal array and after that done by Response Surface newlineMethodology with L31 orthogonal array. The input parameters are voltage, pulse on time, newlinepeak current and powder concentration. The response parameters are material removal rate, newlinetool wear rate, microhardness, surface roughness and white layer thickness. The effect of each newlineinput parameters voltage, pulse on time ,peak current and powder concentration on the newlineresponse parameters material removal rate ,tool wear rate, microhardness, surface roughness newlineand white layer thickness, shown by main plot effect graph for Taguchi and RSM method. newlineContribution of each input parameters by means of percentage is given by ANOVA for newlineTaguchi and RSM method. Also response tables for MRR, tool wear rate, microhardness, newlinesurface roughness and white layer thickness are given. Optimization is done by using gray newlinerelational analysis and with the help of rank order optimized input parameters are calculated. newline newline