EXP1RIMENTATION ON MRR, SURFACE FINISH AND TOOLWEAR ON HSS TOOL STEEL USING DIFFERENT TOOL MATERIALS

Abstract

To investigate on the crystalline structure of HSS 'Fool steel by using different tool materials in EDM process was studied. The several experiments were conducted for analyzing the effect of various predominant EDM process parameter (like working current, pulse on time, spark gap etc.) to the measure the machining response characteristics (like MRR, EWR and SR etc.) by this method in this research work. The work is designed on the basis of experimental designed technique using Taguchi Analysis and followed by analysis of variance (ANOVA) and regression technique. The study on EDM of different input parameters and different mathematical models has been applied to validate the experimental results. Depending upon the weight loss of the workpiece material, all the specimens were analyzed followed by different characterization techniques. In x-ray diffraction study peak broadening has been observed which confirms the change in material properties due to the homogeneous dispersion of the composite particles inside the matrix by this process. By using as Tungsten-Thorium electrode, the lowest average surface roughness of 1 . 12 p.im was observed by Optical surface profiler (OSP) and the lowest average surface roughness of 2.18427 nm was observed by atomic force microscopy (AFM) for sample having the input parameters as current 5 A, pulse on time 60 j.ts and spark gap 6. The higher MRR as a value of 0.0 18876 nigh-nin was observed by having the input parameters as current 7 A, pulse on time 45 ts and spark gap 6 was observed and minimum EWR was as value of 0.01000 rng/min by having the input parameters as current 2 A. pulse on time 60 ps and spark gap 6. Also by using the electrode as Copper based alloy, average lowest surface roughness of 1.19 prn was observed by optical surface profile analysis and by atomic force microscopic, average lowest surface roughness was 9.24619 nm observed as by having the input parameters as current 5 A. pulse on time 60 pis and spark gap of 6. The optimize value of higher MRR (0.015276 mg/mm) and minimum EWR (0.014113 mg/mm) is obtained for having the input parameters as, current 7 A, pulse on time 45 lis and spark gap of 5