Effect of Variation of Electrode Material on Machining Performance of Al 6061 During EDM Operation

Abstract

The machining behaviour of Aluminium alloy 6061 using Electro-Discharge Machining (EDM) is aimed to be investigated by considering three different tool material viz. Copper, Graphite and Brass. The machinability of Aluminium alloy 6061 in EDM is to be analysed in terms of Material Removal Rate (MRR), surface roughness (Ra), and thickness of the recast layer. By considering the following EDM process parameters viz. gap voltage, peak discharge current, pulse-on time, duty factor and dielectric flashing circulation pressure kept at constant values; three different EDM operations are to be carried out on Aluminium alloy 6061 by using aforesaid three electrodes, respectively. Analysis of Scanning Electron Microscopy (SEM) is to be carried out to retrieve surface irregularities that are expected to be produced on EDMed end product of Aluminium alloy 6061. In addition to this, Energy-dispersive X-ray spectroscopy (EDAX) elemental spectra for as received base metal as well as EDMed Aluminium alloy 6061 is to be examined to understand change in chemical composition of the workpiece during EDM operation. Results obtained thereof have also been compared with micro-hardness test data obtained at the top surface of Al6061 EDMed end product.