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Procedia Manufacturing 00 (2017) 000–000

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Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia Manufacturing 20 (2018) 392–399
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Study of Influence of Process Parameters in Electric Discharge
Study of Influence of Process Parameters in Electric Discharge
Machining of Aluminum – Red Mud Metal2017,
Matrix
MESICComposite
Manufacturing
Machining Engineering
of Aluminum –
Society International
Red MudConference
Metal
2017, Vigo (Pontevedra), Spain
Matrix 2017, 28-30 June
Composite
Chinmayee Kar, B.Surekha* , Hemalatha Jena, Suvan Dev Choudhury
Chinmayee Kar, B.Surekha* , Hemalatha Jena, Suvan Dev Choudhury
Costing modelsSchool
forof Mechanical
capacity optimization
Engineering, in Industry
KIIT University, Bhubaneswar, 751024, India 4.0: Trade-off
School of Mechanical Engineering, KIIT University, Bhubaneswar, 751024, India
between used capacity and operational efficiency
Abstract
Abstract
A. Santana
The present paper intends an experimental
a
, P. Afonso
investigation
a,*
, A. Zanin
and mathematical
b
, R.ofWernke
modelling
b
electrical discharge machining (EDM) of
aluminium
The present metal matrix composites.
paper intends an experimentalThe experimentsand
a investigation aremathematical
conducted based on the
modelling of concept
electricalofdischarge
central composite design of
machining (EDM)
University of Minho, 4800-058 Guimarães, Portugal
experimentsmetal
aluminium to estimate
matrix the effect of The
composites. machining processareparameters
bexperiments conductedonbased
responses.
on theInconcept
Unochapecó, 89809-000 Chapecó, SC, Brazil
the present experimental
of central compositeinvestigation
design of
experiments to estimate
discharge current, the effect
open circuit of machining
voltage, process
pulse-on-time areparameters
treated as ontheresponses.
input processIn the present and
variables experimental investigation
material removal rate,
electrode wear
discharge rate open
current, and radial over
circuit cut arepulse-on-time
voltage, considered as the
are responses.
treated as Fifteen experiments
the input with 3 replicates
process variables for each
and material experiment
removal rate,
are conducted
electrode wear onratealuminium
and radialmetal matrix
over cut composites.asThe
are considered the work material
responses. which
Fifteen is used in with
experiments the present studyfor
3 replicates consists of Al7075
each experiment
and 6% red mud
are conducted
Abstract onby weight asmetal
aluminium matrix and reinforcement,
matrix composites. The respectively.
work materialDuring EDM,
which it is in
is used observed that the
the present discharge
study consistscurrent and
of Al7075
and
pulse6% red mud
on-time by significant
have weight as matrix andmachinability
effect on reinforcement, respectively. of
characteristics During EDM, itmetal
Aluminium is observed that the discharge
matrix composite (AMMC). current and
The two
factor analysishave
pulse on-time offers useful information
significant with minimum
effect on machinability deviation for
characteristics controlling metal
of Aluminium the machining parameters
matrix composite to improve
(AMMC). the
The two
Under
accuracy
factor the concept
of the
analysis offers of
EDMed "Industry
components.
useful 4.0",with
information production
minimum processes
deviation for willcontrolling
be pushed the to be increasingly
machining parametersinterconnected,
to improve the
information
accuracy of the based
EDMed on components.
a real time basis and, necessarily, much more efficient. In this context, capacity optimization
goes beyond the traditional
© 2017 The Authors. Published aim byof capacity
Elsevier maximization,
B.V. contributing also for organization’s profitability and value.
© 2017
2018 The
Indeed, The Authors.
lean Published
management
Authors. Published by by
and Elsevier
continuous
ElsevierB.V.B.V.
improvement approaches suggest capacity optimization instead of
Peer-review
© under responsibility of the scientific committee of the 2nd International Conference on Materials
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Peer-review
maximization.
Manufacturing under
Design Engineering.The
and responsibility
study
Design of of
capacity
Engineering.the scientific
optimization committee
and of
costing the 2nd
models International
is an importantConference
research on Materials
topic that deserves
Manufacturingfrom
contributions and both
Design
theEngineering.
practical and theoretical perspectives. This paper presents and discusses a mathematical
Keywords:
model forElectrical
capacity discharge machining,
management material
based onremoval rate,costing
different tool wearmodels
rate, radial overcut,
(ABC andresponse surfaceA
TDABC). methodology
generic model has been
Keywords: Electrical discharge machining, material removal rate, tool wear rate, radial overcut, response surface methodology
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might hide operational inefficiency.
1. Introduction
© 2017 The Authors. Published by Elsevier B.V.
Aluminum under
Peer-review Metalresponsibility
Matrix Composites (AMMC’s)
of the scientific are of
committee newtheage group engineering
Manufacturing Engineering materials which exhibits
Society International superior
Conference
Aluminum
physical andMetal
2017. Matrix properties
mechanical Composites (AMMC’s)
compared are new age group
to non-reinforced alloys.engineering
This makesmaterials which
them suitable forexhibits superior
extensive range
physical and mechanical properties compared to non-reinforced alloys. This makes them suitable
of applications in automotive, aerospace and defense industries. These composite materials have desired properties for extensive range
of applications
such as high
Keywords: in automotive,
Cost strength to weight
Models; ABC; TDABC;aerospace
ratio, and defense
highManagement;
Capacity toughness,Idle industries.
low These
value Operational
Capacity; composite
of coefficient materials have desired properties
of thermal stability and high corrosion
Efficiency
such as high strength to weight ratio, high toughness, low value of coefficient of thermal stability and high corrosion

1. Introduction
* Corresponding author. Tel.: 9776220902.
E-mail
* The address:
Corresponding
cost surekhafme@kiit.ac.in
author.
of idle Tel.: 9776220902.
capacity is a fundamental information for companies and their management of extreme importance
E-mail address: surekhafme@kiit.ac.in
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789 © 2017 The Authors. Published by Elsevier B.V.
in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity
Peer-review underThe
2351-9789 © 2017 responsibility of theby
Authors. Published scientific
Elsevier committee
B.V. of the 2nd International Conference on Materials Manufacturing and
* PauloEngineering.
Design Afonso.
Peer-review Tel.:
under +351 253 510of
responsibility 761;
thefax: +351 253
scientific 604 741 of the 2nd International Conference on Materials Manufacturing and
committee
E-mail
Design address: psafonso@dps.uminho.pt
Engineering.

2351-9789 © 2017 The Authors. Published by Elsevier B.V.


Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.057
2 Author name / Procedia Manufacturing 00 (2017) 000–000
Chinmayee Kar et al. / Procedia Manufacturing 20 (2018) 392–399 393

Nomenclature

AMMC aluminium metal matrix composites


Dt diameter of the tool
Dw diameter of the work piece
EDM electric discharge machining
EWR electrode wear rate
Ip peak current
MRR material removal rate
ROC radial over cut
Ta weight of tool after machining
Tb weight of tool before machining
Ton pulse on time
Vg gap voltage
Wa weight of work piece after machining
Wa weight of work piece before machining

resistance. It is important to note that the machining of complex shapes of high strength materials like composites,
ceramics etc., is very difficult task when using conventional machining process. In the present research work,
authors made an attempt to machine the AMMCs by using EDM process, to develop a nonlinear regression
relationship between process parameters and various responses. Although copper and brass are mostly used as the
electrode material because of their good electric conductivity, sometimes graphite can also be used as a potential
electrode material due to its high melting point, high wear resistance and conductivity. It is important to note that
the most of the researchers have preferred brass, copper and graphite as electrode material in EDM process
In the past, researchers tried to prepare various types of aluminum metal matrix composites [1, 2 and 3] to
introduce tailor made properties that are essential for their functioning in various applications. These materials offer
high resistance for machining with the help of conventional machining processes. Therefore, researchers around the
world used non-conventional machining methods to convert the blanks of AMMCs into useful products. Prakash et
al. [4] prepared A413/flyash/B4C hybrid composites and studied the machinability of the developed composites
using wire EDM. They studied the effect of various input process parameters namely pulse on time, gap voltage,
pulse off time, percentage of reinforcement and wire feed on MRR and surface roughness. Siva et al. [5] developed
in-situ Al-Al2O3-SiC AMMCs and studied their mechanical properties. They also conducted experiments to
investigate the machinability of these prepared hybrid composites. Velmurugan et al. [6] used prepared
Al6061/10%SiC/4%graphite hybrid metal matrix composites using stir casting process and studied the machining
characteristics using EDM. They also used scanning electron microscope to study the surface characteristics of
machined surface. Moreover, Shyha and Rudd [7] also did experiments to study the machining of aluminum matrix
composites reinforced with silicon carbide particles using EDM process after conducting the experiments with the
help of full factorial design of experiments. Harish et al. [8] and Srikanth and Kumar [9] conducted a huge literature
survey and concluded that the machining of aluminum hybrid metal matrix composite is overcome by the Electric
discharge machining process. Further, Rajesh et.al [10] did their experimental investigation on the red mud mixed
AMMC. In their research work, they determined the optimal set of process parameters of CNC lathe machine for a
set of quality characteristics with the help of Taguchi methodology. They also tried to predict the optimal set of
parameters by principal component analysis [11] to improve the performance of the CNC lathe machine on AMMC.
Further, Rajesh et.al [12] conducted the experimental investigation on the Al-12% SiC MMC, which was made by
stir casting process. Required number of experiments were decided based on the concept of response surface
methodology. In addition to that, ANOVA for all the responses had also been conducted. Suresh et al [13]
conducted experiments on the machining of MMCs using EDM. In their work, Al 6351 was used as the matrix
material and silicon carbide (SiC) and boron carbide (B4C) was used as the reinforcing materials. Multi response
optimization was used to find the optimal set of parameters to speed up the machining of high strength aluminum
metal matrix composite. Further, Rao [14] manufactured the AMMCs with rice husk ash and red mud particles as

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