Experimental Analysis of Al-SiC MMC Using Dry Electrical Discharge Machining compared with oil EDM

Abstract

The Dry EDM has mostly used for lower electrode wear, lower discharge gap, small heat affected zone, lower residual stress, lower surface roughness and much more eco-friendly condition. Al-SiC composite has widely used in aerospace and automobile application because of its high hardness, higher wear resistance and light weight. Developed a special attachment of Dry EDM on existing oil EDM machine where liquid dielectric medium is replaced by gaseous medium. Hollow circular shaped copper tool electrode has been used with high speed rotation for supplying the high speed gas passes into discharge gap. All the experiments have been carried out on Al-SiC workpiece using compressed air a dielectric medium and analysed effects of input variables (% SiC, Id, Vg, Ton, rotation speed and Pressure) to the response variables like tool wear rate, material removal rate and surface roughness. ANOVA Analysis has been carried out for effect of input parameters on output parameters. Response surface methodology of cubic centre composite design used for design of experiments for checking the response variables MRR, TWR and SR.