IJSTE - International Journal of Science Technology & Engineering | Volume 2 | Issue 12 | June 2016

ISSN (online): 2349-784X

Experimental Investigation on Metal Removal

Rate of Fabricated Al/SiCp MMC using Electric
Discharge Machining Process
Biplove Thakur
M. Tech Student
Department of Mechanical Engineering
Green Hills Engineering College, Solan

O.S. Bhatia
Associate Professor
Department of Mechanical Engineering
Green Hills Engineering College, Solan

Abstract
Electric discharge machining process is one of the most widely used machining techniques of the present arena. This machining is
proficient of producing complex-shaped electrically conductive or partially conductive portions irrespective of work- piece
hardness owed to its idiosyncratic advantage of non-contact material eliminating process by the electro-thermal mechanism. In this
paper, a metal matrix composite was prepared using Aluminum as matrix and SiC p as reinforcement. The experiments were
performed on the EDM machine to check the metal removal rate and results shows that MRR was found at parametric combination
of A1B3C2D2.
Keywords: Metal Matrix Composite, Silicon Carbide, Electrical Discharge Machine, MMR
________________________________________________________________________________________________________
I.

INTRODUCTION

The original modified EDM model could not predict the temperature profile accurately. A more accurate model is developed and
validated for gas turbine combustion application [1]. In this research, the errors causes were analyzed, and then a layer depth
constrained algorithm (LDCA) and an S-curve accelerating algorithm (SCAA) were proposed to reduce the depth errors [2].This
work proposed a novel method of determining the energy distribution and plasma diameter of EDM. The energy distribution and
plasma diameter were determined by comparing the boundary of the melted material in the crater which was obtained by
metallographic method and the isothermal curve of the thermal-physical model using finite element method (FEM) [3]. In case of
conflicting type performance measures, it is necessary to get possible optimum values of all performances simultaneously, like
higher material removal rate (MRR)with lower average surface roughness (ASR) in electric discharge machining (EDM) process
[4]. The present study discusses about having an overview of the EDM process, modeling of process parameters, and influence of
process parameters such as input electrical variables, pulse shape, and discharge energy on performance measures such as material
removal rate, surface roughness and electrode wear rate [5]. In this work, micro-scale graphite electrodes with a projection area as
small as 0.002 mm2 and 1 mm length have been machined. Process parameter analysis is carried out to analyse the wear behaviour
of micro-scale graphite electrodes during erosion [6]. The concept of schedule monitoring and control as one of the most important
functions of project and program management has not been fully exploited. One possible explanation could be the dominance of
the Earned Value Management System (EVMS, also known as EVM) [7]. EDM drilling is excellent for machining deep and narrow
holes regardless of material hardness and location, whereas die-sinking EDM works well to machine micro-parts and perpendicular
walls of die and molds [8]. Current paper investigates the carbonaceous layer and its formation during the erosion. It is found that
a diamond like amorphous carbon layer embedded with the micro and nano sized metallic debris from the work-piece is deposited
on the erosion front of the electrode. The micro structure of the layer depends on the parameters such as applied current and pulse
duration [9].
II. WORKPIECE MATERIAL
The material for the experimentation i.e. MMC was prepared using aluminum as a matrix and SiC as reinforcement. The SiC
particles were of 63 micron size and were used as 10% by weight. To fabricate the composite, molten aluminum metal was mixed
with the SiC particles by means of mechanical stirring. The mixture was cast with the help of traditional casting method at a
temperature of near about 750C as shown in figure 1.

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72

Experimental Investigation on Metal Removal Rate of Fabricated Al/SiCp MMC using Electric Discharge Machining Process
(IJSTE/ Volume 2 / Issue 12 / 014)

Fig. 1: Casting of MMC

III. EXPERIMENTAL ANALYSIS

The experiments were performed on the EDM to evaluate the metal removal rate of the Al/SiCp metal matrix composite. Figure 2
shows the MRR is found maximum at parametric combination A1B3C2D2 i.e. IP = 10 Amp, Ton = 12 mV, Toff = 100mV, Voltage
= 40 V
SNo
1
2
3
4
5
6
7
8
9

MRR 1
0.0225
0.084
0.105
0.043333
0.043
0.07
0.235
0.076
0.25

Table 1
Metal Removal Rate of Al/SiCp MMC
MRR 2
MRR 3
Average MRR
0.0225
0.02
0.021667
0.098
0.084
0.088667
0.12
0.095
0.106667
0.215
0.126667
0.128333
0.043636
0.047
0.044545
0.073333 0.071667
0.071667
0.24
0.245
0.24
0.08
0.102
0.086
0.22
0.245
0.238333

S/N Ratio, (dB)

-33.2840
-21.0448
-19.4394
-17.8332
-27.0240
-22.8936
-12.3958
-21.3100
-12.4563

Regression for MRR

Summary of Model
S = 0.0299665

R-Sq = 89.94%

R-Sq(adj) = 85.47% PRESS = 0.0363687

R-Sq(pred) = 77.36%

Regression Equation
MRR = -0.00610101 - 0.136939 IP + 0.262061 Toff - 0.241051 Ton + 0.11949 Volt + 0.0487071 IP*Ip + 0.0613737 Ton*Ton 0.0566869 Toff*Toff - 0.0291869 Volt*Volt
Table 2
Analysis of Variance for MRR
Source DF
Seq SS
Adj SS
Adj MS
F
IP
2
0.074554 0.074554 0.037277 41.51
Ton
2
0.022956 0.022956 0.011478 12.78
Toff
2
0.041727 0.041727 0.020863 23.23
Volt
2
0.005247 0.005247 0.002623 2.92
Error
18 0.016164 0.016164 0.000898
Total
26 0.160648
S = 0.0299665 R-Sq = 89.94% R-Sq(adj) = 85.47%

P
0.000
0.000
0.000
0.080

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73

Experimental Investigation on Metal Removal Rate of Fabricated Al/SiCp MMC using Electric Discharge Machining Process
(IJSTE/ Volume 2 / Issue 12 / 014)

M a i n E f f e c ts P l o t f o r S N r a ti o s
Da ta M e a n s
To n

IP

-1 5 . 0
-1 7 . 5

M e a n o f SN ra t io s

-2 0 . 0
-2 2 . 5
-2 5 . 0
1

Vo lt

To f f

-1 5 . 0

-1 7 . 5
-2 0 . 0
-2 2 . 5
-2 5 . 0
1

S ig n a l- to - n o is e : La r g e r is b e tte r

Fig. 2: S/N Ratio for MRR

IV. CONCLUSION
This study concerns the fabrication and experimental investigation of SiCp assisted metal matrix composite. The conclusions
obtained from this investigation are as follow:
The fabrication of Al/SiCp was successfully completed using mechanical stir casting process.
The composite was successfully machined using electrical discharge machining process and the best parametric
combination for the maximum metal removal rate was found to be A1B3C2D2 i.e. IP = 10 Amp, Ton = 12 mV, Toff =
100mV, Voltage = 40 V.
From the analysis of variance it was found that for Material removal rate, current, pulse off time and Pulse on time are
the most significant factors.
Mathematical regression model was obtained from experimental data for material removal rate with R 2 value 89.94% .
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