COMPARATIVE ANALYSIS OF MILD STEEL

BEFORE AND AFTER STABILIZATION AND

EVALUATE MACHINE PARAMETERS USING ECM
 ABSTRACT

Heat stabilized process is an additive advanced technology for the

fabrication of metal parts through layer wise deposition and heat induced
melting of metal and zirconium powder. The heat stabilized treated mild
steel surface after then applying zirconium oxide deposition process. In the
future, these technologies might play a greater role in metal finishing
operations. This study focuses on the effects of surface wear strength and
strategies to improve the surface finish of the components. Zirconium oxide
because it has a lower wear rate with high contact pressure as well as
higher hardness. To measure the mechanical behavior of mild steel
materials surface hardness
 INTRODUCTION

The basic ECM process is really quite simple. An electrical spark is

created between an electrode and a work piece. The spark is visible
evidence of the flow of electricity. This electric spark produces intense heat
with temperatures reaching 8000 to 12000 degrees Celsius, melting almost
anything. The spark is very carefully controlled and localized so that it only
affects the surface of the material. The ECM process usually does not affect
the heat treat below the surface. With wire ECM the spark always takes
place in the dielectric of deionized water. The conductivity of the water is
carefully controlled making an excellent environment for the ECM process.
The water acts as a coolant and flushes away the eroded metal particles.
 LITRATURE SERVEY

• Yeo et al. (1999) investigated the current attempts to improve micro hole
drilling. The focus is to develop a novel technique that enhances the capabilities
of Micro-ECM for realization of micro holes with a high aspect ratio. Based on
theories in fluidization engineering and ultrasonic degassing, a method of
introducing ultrasonic vibrations into Micro-ECM processes is conceptualized
and developed. A comparative analysis has revealed that the new technique can
produce a significant increase in the aspect ratios over the current methods of
micro hole drilling. The potential of the capabilities of ultrasonic vibrations in
Micro-ECM drilling is thus emphasized.
• Ho and Newman (2003) presented the review of vast research work carried out
from the inception to the development of die-sinking ECM within the past
decade. It reports the ECM research relating to improving performance
measures, optimizing the process variables, monitoring and control of sparking
process, simplifying the electrode design and manufacturing. A range of ECM
applications were highlighted together with the development of hybrid
machining processes
 LITRATURE SERVEY
• Puri and Bhattacharyya (2003) carried out an
experimental investigation based on Taguchi method
involving thirteen control factors in WECM process
comprising a rough cut followed by a trim cut. The main
influencing factors were determined for given machining
criteria such as average cutting speed, surface finish
characteristics and geometrical inaccuracy caused due to
wire lag.
• Prohaszka et al. (1997) reported the requirements of wire
electrode materials for improving WECM performance.
Three kind of wire material namely Mg, Sn and Zn were
selected to perform the experiments. It was concluded
that the materials used for the fabrication of wire
electrodes must be characterized by a small work function
and high melting and evaporation temperatures.
 SELECTION OF MATERIALS

1.MILD STEEL

2.ZIRCONIUM OXIDE
 PROCESS FLOW

1. PLATE – ZIRCONIUM 3% DEPOSITION

2. PLATE – ZIRCONIUM 2% DEPOSITION

3. PLATE – ZIRCONIUM 1% DEPOSITION

4. PLATE – NON DEPOSITION

ECM MACHINING
 TESTING

1. ECM process machining parameters

 ADVANTAGE
Metal having any hardness or brittleness and toughness
can be machined.
• Harder materials such as steel alloys or tungsten
carbides which are used for molding and other non-
conventional machining like forging and press tools can
be reproduced.
• Dies can be machined at hardened condition.
• Complicated shapes can be reproduced.
• Very fine holes can be done very accurately.
• The accuracy is very high. Tolerance of 0.005 mm can
be achieved.
• Wear resistance surface can be made because work
pieces produced with EDM have micro-craters which
can contain lubricants effectively.
 APPLICATION

• Generally ECM is hugely used for

machining burr free intricate shapes as well as
narrow slots and blind cavities. Sinking of dies,
plastic molding, die casting compacting, cold
heading, extrusion, press tools, wire drawings are
some of the examples of its application. Negative
tool geom/p if suitable tool can be made. ECM is
very useful for machining small holes. It is etry
can also be generated on a w also used to cut slot
in diesel fuel injection nozzles. It is also used in
air crfat engines and brake valves etc.
 REFERENCE
1. Junkar, M.; Sluga A.: Competitive Aspects in the Selection of
Manufacturing Processes, Proceedings of the 10th Int. Conference on
Applied Informatics, 10-12 February, Innsbruck, Austria, 1992, 229-230
2. -XQNDU 0 )LOLSLþ % *ULQGLQJ 3URFHVV &RQWURO 7KURXJK
0RQLWRULQJ DQG 0DFKLQH Learning, 3rd Int. Conference “Factory
2000”, University of York, UK, 27 - 29 July, 1992, 77-80.
3. Junkar, M.; Komel, I.: Modeling of the Surface Texture generated by
Electrical Discharge Machining, Proceedings of the 12th IASTED
International Conference on Modeling, Identification and Control,
Insbruck, Austria, Acta Press 141 – 142
XQNDU0)LOLSLþ%äQLGDUãLþ0$Q$,$SSURDFKWRWKH6HOHFW
LRQRI'LHOHFWULF in Electrical Discharge Machining, presented at the
3.rd Int. Conf. on Advanced Manufacturing Systems and Technology,
AMST 93, Udine, 1993. 11-16. DEEP SMALL HOLE DRILLING WIT
THANK YOU