Optimization of Electrochemical Grinding Parameters for Effective Finishing of Hybrid Al/(Al2O3+ZrO2) MMC

Optimization of Electrochemical Grinding Parameters for Effective Finishing of Hybrid Al/(Al2O3+ZrO2) MMC

K.Z. Molla (Department of Mechanical Engineering, Punjab Campas, Chitkara University, Rajpura, Punjab, India) and Alakesh Manna (Department of Mechanical Engineering, PEC University of Technology, Chandigarh, Punjab, India)
DOI: 10.4018/ijseims.2013070104
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Abstract

In this study, the Taguchi method, a powerful tool in the design of experiment is used to optimize electrochemical grinding (ECG) parameters for effective finishing of hybrid Al/(Al2O3+ZrO2) MMC using a resin bonded cupper impregnated diamond grinding wheel. An orthogonal L27 (313) array is used for 35 factorial design and analysis of variance (ANOVA) is employed to investigate the influence of grinding wheel speed, electrolyte concentration, D.C. supply voltage, current density and work-piece speed on the surface finish, Ra and Rt respectively. Test results reveal that the Ra and Rt both are lesser at moderate grinding wheel speed i.e. 9000 rpm with current density 0.25A/mm2 and 30% electrolyte concentration. Taking all five parameters considered for experimentation and using multivariable higher order regression, mathematical models for surface finish, Ra and Rt are established to investigate the influence of Electrochemical Grinding (ECG) parameters during finishing of hybrid Al/(Al2O3+ZrO2) MMC. Confirmation test results established that the developed mathematical models are appropriate for effective representing the surface finish criteria, Ra and Rt (µm).
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2. Planning And Design For Experimental Study

An electrochemical grinding setup has been designed, fabricated and utilized for experimental investigation. Figure 1 shows schematic block diagram of the designed and fabricated electrochemical grinding (ECG) setup, which has four different units. Figures 2, 3(a), 3(b) and 4 show the details of the schematic diagram of each unit of fabricated ECG setup i.e. main power supply unit, tool rotational and feed motion unit, work-piece rotational and x-y movement unit, and electrolyte flow control unit respectively.

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