Title: Electrical discharge machining of Al (6351) alloy: role of electrode shape

Authors: S. Suresh Kumar; M. Uthayakumar; S. Thirumalai Kumaran; P. Parameswaran; E. Mohandas

Addresses: Faculty of Mechanical Engineering, Kalasalingam University, Krishnankoil – 626126, India ' Faculty of Mechanical Engineering, Kalasalingam University, Krishnankoil – 626126, India ' Faculty of Mechanical Engineering, Kalasalingam University, Krishnankoil – 626126, India ' Physical Metallurgy Group, Indira Gandhi Centre for Atomic Research, 603102, Kalpakkam, India ' Physical Metallurgy Group, Indira Gandhi Centre for Atomic Research, 603102, Kalpakkam, India

Abstract: In this work, an investigation is made in order to identify the influence of machining parameters such as pulse current (I), pulse on time (Ton) and pulse duty factor (τ) on the electrical discharge machining (EDM) of aluminium (6351) alloy. The effect of electrode shape viz. circular and square configuration on the machining characteristics namely electrode wear ratio (EWR), surface roughness (SR) and over cut (OC) were analysed. The experimental results revealed that the circular electrode exhibits lower EWR, better surface finish and minimised OC when compared to the square electrode. The surface characteristics of the aluminium alloy machined by both the electrodes are also examined by using scanning electron microscope (SEM). The mechanism of crater formation and the surface texture of the machined area are also discussed.

Keywords: electrical discharge machining; EDM; electrode shape; electrode wear ratio; EWR; surface roughness; overcut; surface quality; electro-discharge machining; aluminium alloys; pulse current; pulse on time; pulse duty factor; circular electrodes; surface finish; square electrodes; crater formation; surface texture.

DOI: 10.1504/IJMPT.2016.076378

International Journal of Materials and Product Technology, 2016 Vol.53 No.1, pp.86 - 97

Received: 15 May 2015
Accepted: 31 Oct 2015

Published online: 26 Mar 2016 *

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