Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels

Nowadays, electrical discharge machining (EDM) is the non-conventional method that has been used extensively in machining hard material that is commonly used in mold and die industry but the limitations of EDM will cause lower productivity and poor surface quality. EDM becomes most apparent by us...

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Main Author:	Idris, Muhammad Ridzuan
Format:	Thesis
Language:	English English English
Published:	2015
Subjects:	TJ1125-1345 Machine shops and machine shop practice
Online Access:	http://eprints.uthm.edu.my/1645/2/MUHAMMAD%20RIDZUAN%20IDRIS%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/1645/1/24p%20MUHAMMAD%20RIDZUAN%20IDRIS.pdf http://eprints.uthm.edu.my/1645/3/MUHAMMAD%20RIDZUAN%20IDRIS%20WATERMARK.pdf
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spelling	my-uthm-ep.16452021-10-04T01:25:29Z Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels 2015-04 Idris, Muhammad Ridzuan TJ1125-1345 Machine shops and machine shop practice Nowadays, electrical discharge machining (EDM) is the non-conventional method that has been used extensively in machining hard material that is commonly used in mold and die industry but the limitations of EDM will cause lower productivity and poor surface quality. EDM becomes most apparent by using powder metallurgy electrode together with chromium (Cr) powder suspension into the dielectric fluid which has led to the increasing of productivity and good quality performance and characteristics. Therefore, by combining of both EDM parameters and machining conditions by incorporating with specific magnetic system plus integrated with existing filter system, it is highly expected that the machining speed can be enhanced. However, there are difficulties to determine the best combination of these machining parameters in order to increase the material removal rate (MRR) and at the same time to reduce the electrode wear rate (EWR) with the acceptable surface integrity. This research emphasizes the studies of Cr powder mixed in EDM machining of AISI D2 hardened steel using copper tungsten electrode which has been done successfully. Data were analysed using design of three factors at a time consisted of peak current (Ip), pulse-on (Pon) and powder concentration(C). Discussions were made on the responses such as MRR, EWR, Surface Roughness (Ra), surface morphology, recast layer (RL) and microhardness (MH) on the selected samples from the same machining conditions. Results have proved that Ip was the most significant parameter which has influenced the machining responses on Cr powder mixed EDM of AISI D2. It is also found that proper powder concentration of 2gram/litre enhanced the machining efficiency particularly in MRR. Furthermore, introduction of proper addition of Cr powder in the dielectric also decreased Ra and RL thickness. The EWR increased as the peak current increased, but inversely with pulse-on. In general, the possibility of EDM process for machining AISI D2 tool steel by incorporating Cr powder mixed in the dielectric is acceptable and the entire objectives were successfully proven. 2015-04 Thesis http://eprints.uthm.edu.my/1645/ http://eprints.uthm.edu.my/1645/2/MUHAMMAD%20RIDZUAN%20IDRIS%20COPYRIGHT%20DECLARATION.pdf text en staffonly http://eprints.uthm.edu.my/1645/1/24p%20MUHAMMAD%20RIDZUAN%20IDRIS.pdf text en public http://eprints.uthm.edu.my/1645/3/MUHAMMAD%20RIDZUAN%20IDRIS%20WATERMARK.pdf text en validuser mphil masters Universiti Tun Hussein Onn Malaysia Faculty of Mechanical and Manufacturing Engineering
institution	Universiti Tun Hussein Onn Malaysia
collection	UTHM Institutional Repository
language	English English English
topic	TJ1125-1345 Machine shops and machine shop practice
spellingShingle	TJ1125-1345 Machine shops and machine shop practice Idris, Muhammad Ridzuan Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
description	Nowadays, electrical discharge machining (EDM) is the non-conventional method that has been used extensively in machining hard material that is commonly used in mold and die industry but the limitations of EDM will cause lower productivity and poor surface quality. EDM becomes most apparent by using powder metallurgy electrode together with chromium (Cr) powder suspension into the dielectric fluid which has led to the increasing of productivity and good quality performance and characteristics. Therefore, by combining of both EDM parameters and machining conditions by incorporating with specific magnetic system plus integrated with existing filter system, it is highly expected that the machining speed can be enhanced. However, there are difficulties to determine the best combination of these machining parameters in order to increase the material removal rate (MRR) and at the same time to reduce the electrode wear rate (EWR) with the acceptable surface integrity. This research emphasizes the studies of Cr powder mixed in EDM machining of AISI D2 hardened steel using copper tungsten electrode which has been done successfully. Data were analysed using design of three factors at a time consisted of peak current (Ip), pulse-on (Pon) and powder concentration(C). Discussions were made on the responses such as MRR, EWR, Surface Roughness (Ra), surface morphology, recast layer (RL) and microhardness (MH) on the selected samples from the same machining conditions. Results have proved that Ip was the most significant parameter which has influenced the machining responses on Cr powder mixed EDM of AISI D2. It is also found that proper powder concentration of 2gram/litre enhanced the machining efficiency particularly in MRR. Furthermore, introduction of proper addition of Cr powder in the dielectric also decreased Ra and RL thickness. The EWR increased as the peak current increased, but inversely with pulse-on. In general, the possibility of EDM process for machining AISI D2 tool steel by incorporating Cr powder mixed in the dielectric is acceptable and the entire objectives were successfully proven.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Idris, Muhammad Ridzuan
author_facet	Idris, Muhammad Ridzuan
author_sort	Idris, Muhammad Ridzuan
title	Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
title_short	Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
title_full	Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
title_fullStr	Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
title_full_unstemmed	Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels
title_sort	effects of chromium powder mixed in electrical discharge machining of aisi d2 hardened steels
granting_institution	Universiti Tun Hussein Onn Malaysia
granting_department	Faculty of Mechanical and Manufacturing Engineering
publishDate	2015
url	http://eprints.uthm.edu.my/1645/2/MUHAMMAD%20RIDZUAN%20IDRIS%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/1645/1/24p%20MUHAMMAD%20RIDZUAN%20IDRIS.pdf http://eprints.uthm.edu.my/1645/3/MUHAMMAD%20RIDZUAN%20IDRIS%20WATERMARK.pdf
_version_	1747830836815724544

Effects of chromium powder mixed in electrical discharge machining of AISI D2 hardened steels

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