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Effect of Current in the EDM Machining of Aluminum 6061 T6 and its Effect on the Surface Morphology

  • Research Article - Mechanical Engineering
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Abstract

Electric discharge machining (EDM) produces a recast/white layer on the surface of the machined workpiece. Machining with EDM generally produces a higher surface roughness as compared to conventional machining processes. The operating parameters in EDM, i.e., “current”, “voltage”, “on time” and “off time” are directly related with the white layer formation, its thickness, morphology and roughness. Machining of Al 6061 T6 cylinders is performed on die-sinking EDM machine with varying electric current values to determine its effect on surface morphology in the case of aluminum alloy. Material removal rate versus current is determined for different current values. An attempt is made to relate the globule formation on the machined surface, with the machining current. Scanning electron microscopy, optical microscopy and material composition study through energy dispersive spectrography are performed. The white layer thickness, globule diameter and inter-globule distance are found to increase with the increase in electric current.

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Abbreviations

MRR:

Material removal rate (m3/min)

AWLT:

Average white layer thickness (μm)

AGD:

Average globule diameter (nm)

IGD:

Inter-globule distance (nm)

SG:

Spark gap (mm)

SEM:

Scanning electron microscopy

EDS:

Energy dispersive spectrograph

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Engineering and Technology Taxila, Taxila, Pakistan

    Samra Arooj, Masood Shah & Shahab Khushnood

  2. School of Mechanical and Manufacturing Engineering (SMME), NUST, Islamabad, Paksitan

    Shahid Sadiq & Syed Hussain Imran Jaffery

Authors
  1. Samra Arooj
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  2. Masood Shah
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  4. Syed Hussain Imran Jaffery
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  5. Shahab Khushnood
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Correspondence to Samra Arooj.

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Arooj, S., Shah, M., Sadiq, S. et al. Effect of Current in the EDM Machining of Aluminum 6061 T6 and its Effect on the Surface Morphology. Arab J Sci Eng 39, 4187–4199 (2014). https://doi.org/10.1007/s13369-014-1020-z

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  • DOI: https://doi.org/10.1007/s13369-014-1020-z

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