Soumya Seminar Report
Soumya Seminar Report
Soumya Seminar Report
SUBMITTED BY
SOUMYA
PANIGRAHI
REGD. NO:
ROLL NO:
TH
8 SEMESTER
B.TECH,
RANJAN
1201105224
31333
ENGG.
MECHANICAL
GUIDED BY
Mr. ANANT KUMAR DAS
DEPARTMENT OF MECHANICAL ENGINEERING,
IGIT, SARANG-759146, ODISHA
CERTIFICATE
This is to certify that the seminar report entitled "DEVELOPMENT IN THE
NON TRADITIONAL MACHINING OF PARTICLE REINFORCED
METAL MATRIX COMPOSITES" by Soumya Ranjan Panigrahi of B.Tech,
8th semester, Mechanical Engineering of academic year 2015-2016 in partial
fulfillment of requirement for the award of Degree of Bachelor of Technology in
Mechanical Engineering, Indira Gandhi Institute of Technology, Sarang, under
BPUT, Rourkela, is submitted under my guidance.
Dr. A. Mishra
Head of the Department
ACKNOWLEDGEMENT
I avail this opportunity to express my hereby indebtedness, deep gratitude and
sincere thanks to my supervisor Mr. Anant Kumar Das, Department of Mechanical
Engineering, for his depth supervision and guidance, constant encouragement and
co-operative attitude for helping me bring out this seminar paper.
I am extremely thankful to our department which gave me the opportunity to
prepare a seminar on this topic and present it. I would also thank Dr.Antaryami
Mishra, the Head of the Department, Mechanical Engineering, for giving me a
suitable date to speak on.
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Finally I extend my sincere thanks to all those who have helped me during my
seminar work and have been involved directly or indirectly in my endeavor.
ABSTRACT
The non-traditional machining of particulate reinforced metal matrix composites is
relatively new. However, researchers seem to pay more attention in this field
recently as the traditional machining of particulate reinforced metal matrix
composites is very complex. This research investigates different nontraditional
machining, such as electro-discharge, laser beam, abrasive water jet, electrochemical and electro-chemical discharge machining of this composite materials.
The machining mechanism, material removal rate/machining speed and surface
finish have been analysed for every machining process. This analysis clearly shows
that vaporisation, melting, chemical dissolution and mechanical erosion are the
main material removal mechanisms during non-traditional machining. The thermal
degradation and the presence of reinforcement particles mainly damage the
machined surface. The understanding of electro discharge, laser beam and abrasive
water jet machining is more developed than that of electro-chemical and electrochemical discharge machining for particulate reinforced MMC.
CONTENTS:
TOPIC
PAGE NO.
1. INTRODUCTION
2. ELECTRICAL DISCHARGE MACHINING
3. LASER BEAM MACHINING
4. ABRASIVE WATER JET MACHINING
5. ELECTROCHEMICAL MACHINING
6. ELECTROCHEMICAL SPARK MACHINING
7. CONCLUSION
8. REFERENCES
1. INTRODUCTION
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as die-sinking and wire. The shape of the die is machined into workpiece
by feeding the die into workpiece in the die-sinking EDM. On the other
hand, in wire electro-discharge machining (WEDM) a thin wire is used as
the tool electrode [1,7]. The size of the cut is always bigger than the size of
the tool or wire in EDM. This is known as overcut, which is constrained by
the minimum distance (between electrodes) necessary for spark. As the
material removal in this process takes place through melting and
vaporisation, a recast layer of workpiece material on the surface and a heat
affected zone below the surface of the workpiece are generated.
particle is partly in solid material and partly inside the projection of wire
diameter (PPWD) (iii) the particle is partly in solid material and partly in
melted material (PPMM).
2.2: TOOL WEAR AND BREAKAGE
Electrode with higher melting temperature has better wear resistance
during EDM. For example, the wear rate of brass is greater than copper
due to the higher melting temperature of copper. Tool wear rate on the
negatively connected electrode is less than the positively connected
electrode irrespective of the electrode material and the volume percentage
of reinforcements. A rotary electrode increases material removal rate,
decreases electrode wear and improves surface finish compared to a
stationary electrode [33,34]. While performing WEDM on 6061Al alloys,
10 vol% Al2O3p/6061Al composite and 20 vol% Al2O3p/ 6061Al
composite Yan et al noted that the wire tends to break near the middle of
the machined surface for all the materials, when a lower discharge energy
(current 20 A, pulseon time 3.5ms) was applied. But this location of wire
break changed when the discharge energy (current 22 A, pulse-on time
3.8ms) increased. In this case wires break below the middle, at the middle
and above the middle of 6061Al alloy and, 10 vol% Al2O3p/ 6061Al and
20 vol% Al2O3p/6061Al composite machined surfaces.
width of the cut opening (kerf width). The effectiveness of the LBM
process of any material depends mainly on the thermal properties and
partially on the optical properties rather than on the mechanical properties
of that material. Therefore, materials with favourable thermal properties,
such as low thermal diffusivity and conductivity, regardless of brittleness
or hardness, are particularly well suited for laser machining. The heat
energy transfers from the laser to the material through irradiation in this
process. Thus, cutting forces, mechanically induced material damage, tool
wear and machine vibration are absent. The laser beam can be used for
drilling, cutting, grooving, welding and heat treating processes on a single
machine when attached with a multi-axis workpiece positioning system Of
robot.CO2and Nd:YAG lasers are the most established among many types
of lasers used for machining in industries.
3.1: MACHINING MECHANISM:The stages during LBM are (i) melt, vaporise and chemical degrade, (ii)
remove transformed material and (iii) cool down. Initially the high energy
density laser beam is focussed on work surface and thermal energy
transfers from the laser beam to the workpiece material. This thermal
energy absorbed by the workpiece heats and transforms the work volume
into a molten, vaporised or chemically changed state. Then a high-pressure
inert gas jet is used to prevent oxidation and remove the transformed
material from the machining zone. The melted materials that are not
removed cool down, solidify and form the machined surface. Generally the
diameter of a laser beam (E0.25 mm) is much bigger than that of the
reinforcements (115mm) in commonly used MMCs. A typical LBM
process of MMC. Unlike the EDM process, the reinforcement particles
melt during LBM and substantial changes take place in the microstructure
of MMC. In this case the laser beam focused on the top of the workpiece
surface or little bit below the top surface . Thus the workpiece material
starts to melt, vaporise and degrade from the top and continues towards
the bottom. The high-pressure gas jet forces the transformed material
towards the bottom and causes downward flow of the molten material
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very similar in size compared to the abrasive particles in the water jet and
(iii) reinforcement particles in MMC are much larger than abrasive
particles in the water jet. In case when the size of abrasive particle is
bigger than the reinforcement particles (as in Fig. 2(a)), an abrasive
particle removes material which includes several reinforcement particles.
In this case, there are chances of fracture and pull out of reinforced
particles when those are partly in the matrix material and partly in the path
of abrasive particles. In this case the effect of reinforcement particles on
the surface finish is negligible compared to the effect of abrasive particles.
With the decrease of the abrasive particle size it becomes unable to
remove a full reinforcement particle at a time when both particles have
similar size. In this situation the abrasive particles push the reinforcements
in the surface and over the surface which cause indentation and ploughing,
respectively. When the abrasive particles are very small, as shown in Fig.
2(b), the capacity to remove material for each abrasive particle is very
less, which is much smaller than the size of reinforcement. Thus, the
abrasive particles remove matrix as well as reinforcement materials
progressively and smooth surfaces are generated.
4.2: CUTTING SPEED
The cutting speed of water jet machining is also an input parameter. The
time for material removal per unit area decreases with the increase of
speed. Therefore at higher speed lower depth of cut will be achieved. In
addition, surface roughness increases and striations become more visible
at higher cutting speed.
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Fig 3:- Effect of cutting speed on the average surface roughness for
different abrasive sizes
Fig.3 shows that the surface roughness obtained in MMC machined by
AWJ increases with the increase of cutting speed. It also shows that the
bigger abrasive particles produce a rougher machined surface. It is
interesting to note that when the particle size increases, the rate of
increase of surface roughness increases with speed.
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5. ELECTROCHEMICAL MACHINING
In electrochemical machining (ECM), the material, mainly metal, is
removed by controlled electrochemical dissolution process of a workpiece
where workpiece and tool are anode and cathode, respectively, and those
are separated by an electrolyte. The ECM starts when an electric current is
passed through the electrolyte. At this stage, the anodic workpiece dissolves
locally and the shape of the removed material in the workpiece is
approximately a negative mirror image of that of the tool. The electrolyte is
generally a concentrated salt solution. It is pumped through the machining
gap at high velocity to remove the reaction products and to reduce heat
generation. Machining performance in ECM is controlled by the anodic
behavior of the workpiece material in a given electrolyte. The ECM process
is capable of manufacturing complex shapes as well as miniature parts
regardless of hardness of workpiece material. In addition, there are several
attractive advantages of electrochemical machining such as no burrs, no
stress, a longer tool life, damage-free machined surface, etc. This method
has the capability to manufacture parts for the aerospace,
automotive,defence,medical and electronics industries: for example turbine
blades, engine castings, bearing cages, gears, dies and moulds, artillery
projectiles, surgical implants and micro-machining components.
5.1: MACHINING MECHANISM
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A voltage is applied while keeping the workpiece and tool at anodic and
cathodic ends, respectively, in an electrolyte solution. Senthil kumar used
copper with a square cross section as tool and fresh NaCl solution as
electrolyte, which was axially fed to the cutting zone through a central hole
of the tool during machining Sic/Al MMC. Other electrolytes such as
potassium nitrate, potassium chloride, sodium nitrate and sodium chloride
can be used for ECM of metal matrix composites. During this process, the
tool is advanced towards the workpiece in a defined path and the required
shape of the workpiece is achieved by using a suitable tool. Hihara used
calomel and aqueous sodium nitrate solution as cathode and electrolyte,
respectively. Dissolution occurred by the electrolytic removal of the matrix
material, while the inert reinforced particles are flushed away by the
electrolyte. Hihara machined the MMC material and achieved tolerances of
approximately 0.05 mm by maintaining small distances of approximately
0.0250.75 mm between the material and the tool. Current density of equal
to or greater than approximately 1 A/cm 2 was applied. The current density
varied depending on the electrochemical machine used. Though current
density in the range of 110 A/cm 2 was used, current density of 2.5 A/cm 2 is
preferred. The cavity generally conforms to the shape of the cathode (i.e.
tool). Electrochemical machining continues until the desired shape of the
MMC material is formed. During electrochemical machining, material
removal rate increases with the increase of the applied voltage, feed,
electrolyte concentration and flow rate. Increased voltage and electrolyte
concentration result in a higher machining current in the interelectrode gap.
Increased feed also increases the current density due to the reduction in
inter-electrode gap. At a higher electrolyte flow rate, ions from the metal to
the solution are more mobile to speed up the chemical reactions, thus
increasing the metal removal rate.
5.2 SURFACE FINISH
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Fig shows that at low voltage and feed rate surface roughness is higher.
This is because of unsteady and non-uniform anodic metal dissolution. At
low current density surface etchings reveal etch pits and preferred grain
boundary is attacked, which cause uneven microstructure and thus leads to
a rougher surface.
discharges occur if the voltage is higher than a critical value which depends
on the geometry and concentration of the electrolyte. At or above the
critical voltage the production of gas bubble is very high and these coalesce
into a gas film which isolates the tool electrode from the electrolyte. At this
stage the electrical field in this film is very high and generates electrical
discharges across these bubbles but not between electrodes. The heat from
discharges and probably some chemical etching contribute to the eroding of
the workpiece when it is positioned near the electrode. The workpiece is
held at a fixed distance from the anode and brought close to the cathode so
that material removal could take place in the region where sparking occurs.
This is the case when machining on conductive materials. However, MMCs
are conducting materials though non-conductive particles are reinforced
into these materials.
6.1 MACHINING MECHANISM
The material is removed by the complex physicalchemical actions where
electro-chemical dissolution (ECD) and electro discharge erosion (EDE)
take place simultaneously. Sodium nitrite (NaNO 3 ) and sodium hydroxide
(NaOH) are two commonly used electrolytes which provide limited
conduction between the tool and the workpiece during machining of MMC.
Fig. 28presents a typical electro-chemical discharge machining of particle
reinforced MMC. In this case, tool and workpiece electrodes act as cathode
and anode, respectively, where a pulsed DC voltage is applied between the
electrodes which lead to the flow of current across the machining gap and
anodic dissolution of the workpiece takes place. The electro-chemical
reactions also take place in the same time and increase the number of
hydrogen bubbles at the cathode surface, which increases the electrical
resistance and voltage between the cathode and the anode. When this
voltage reaches a critical value, the sparks are initiated. Thus, the electric
discharge takes place between the tool and the MMC workpiece. The
performance of ECDM depends on the machined surface, such as the form
of the anodic surface film and the amount of gas evolution.
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