Love Kishore Sharma

The concept Electrochemical machining (ECM) is broadly implemented in manufacturing area for the past two decades because of several advantages e.g. almost negligible tool wear, resistance of W.P. to thermal and mechanical stress and strain and the ease to form complicated shapes in tough material. Several optimization techniques had been implemented for studying the process factors of different non-conventional machining processes. Analysis of surface texture by implementation of RSM had been discussed by authors but they have not included the ROC& MRR. A precise investigation of ROC and MRR is studied in detail. Our aim for the present work is to optimize the independent parameter of ECMM using S1 tool steel also called as shock resistant tool steel, for maximizing the amount of material removal and for minimizing the radial over cut using RSM. The multi-parameter examinations of the MRR and ROC obtained from RSM have been in depth analysed by contour and surface plots. Voltage is maximum effect on machining rate whereas the E.C. largely affects ROC in comparison to other parameters. The optimum performance parameters for ECMM setup are determined for future investigation.

Electric Discharge Machining (EDM) is an alternative machining process to traditional machining process for the precise machining of complex shaped electrically conductive machine parts. In EDM, machining is not affected by the mechanical properties of workpiece. The material is removed by spark erosion process. It is commonly used in advanced industry in which precise part of high quality required such as the aerospace, automobile, die manufacturing and moulds industries to machine hard metals and its alloy. The economics of machining depends on the proper selection of EDM machining parameters, tool material and dielectric. Dielectric fluid have significant impact on EDM processes. The AISI 4140 steel is a chromium-manganese-molybdenum grade used for making the dies for plastic injection moulds, extrusion dies for thermoplastics and for compression moulds.