DEPARTMENT OF MECHANICAL ENGINEERING

KARPAGAM UNIVERSITY
ME- MANUFACTURING
In this project a new combination of composite material have been proposed. Though there are
many combinations of composites in use, aluminum is more applicable in mechanical as well as
aerospace industry. To meet the needs of aluminum composites in the aviation material industries this
combination is proposed.
This composite has the combinations like Aluminum, Fly ash, Magnesium oxide and the
proportions are 90%, 5%, 5%, respectively. Fabrication of the composite is done by stir casting method.
Then the thickness of the fabricated composite is reduced by sheet rolling process. The thin sheet of
aluminium is cut short to 50x50 mm. This is done to test the material in EMM (electro chemical
micromachining).
In EMM (electro chemical micromachining) the (reduced thickness) fabricated specimen is
tested by setting the three factors i.e. fixing the levels of voltage, electrolyte concentration, frequency.
These factors are set at three different levels to perform L29 orthogonal array of experiments, which is
more accurate in finding the machining parameters.
The specimen is weighed and is noted. Then holes are drilled using the titanium drill tool. The
radius of the drilled hole is founded and it is weighed, readings re noted. While machining the specimen,
the machining time and S/N curve for overcut and MRR is noted. This step is repeated to 27
experimental runs by changing the levels of voltage, electrolyte concentration and frequency.
Using the above readings of weight, overcut can be founded. Similarly using the radius reading
and machining time, MRR can be founded. Finally the S/N graph for overcut and MRR is generated. This
curve will be used to find the optimal values like voltage, electrolyte concentration and frequency for
MRR and overcut.
It is founded that minimum value for overcut and maximum value for MRR. The optimal values
for maximum MRR were machining voltage of 7 V, electrolyte concentration of 24 g/l, and frequency of
50 Hz. The optimal values for minimum overcut were machining voltage of 9 V, electrolyte
concentration of 18 g/l, and frequency of 50 Hz.
To verify the above test a confirmation test is done by repeating the predicted value. Based on
the Verification test, the improvements of the MRR from the initial machining parameters to the optimal
machining parameters are about 35.5 % and the Overcut is improved by 18.04 %
NAME: B.BABU
REG.NO:11WMEMF014
GUIDE NAME:R.RAGOTH SINGH