Performance study of electrical discharge machining process in burr removal of drilled holes in Al 7075

Deburring is the finishing technique that is very essential for the manufacturing of precise components. Although there are various methods to remove burrs but sometimes technology requires new innovative ideas for better outcome irrespective of cost. Deburring with greater efficiency and full automation is a difficult task and this thing leads to use unconventional approaches. This research paper is all about deburring through Electric Discharge Machining process (EDM), which can be useful for finishing materials with very high precision with no men interference. For successful utilization of deburring through EDM, more intensive research including control parameters analysis of the process, is still required. In this research, the drilling operation was done on the specimen to obtain burrs and comparative study was done with different parameters and different electrodes for deburring effectively through EDM. The variable parameters were discharge current, pulse time on and pulse time off and other parameters were remained constant. Material removal rate, tool wear rate and burr height were studied as output parameters to analyse *Corresponding author: Pretesh John, Department of Mechanical Engineering, Shepherd School of Engineering & Technology, SHIATS-DU, Allahabad, India E-mail: [email protected] Reviewing editor: Zude Zhou, Wuhan University of Technology, China Additional information is available at the end of the article ABOUT THE AUTHORS Pretesh John is a MTech. (Production & Industrial Engineering) research scholar in the Department of Mechanical Engineering, SSET, SHIATS, Allahabad, India, and has been working on deburring techniques, performed for burr removal on various engineering materials. He has published one article on deburring through EDM in an International Journal and has presented one research in an International Conference in Malaysia. Rahul Davis is an Assistant Professor in the Department of Mechanical Engineering, SSET, SHIATS, Allahabad, India. He has performed much research related to metal cutting and finishing operations on various engineering materials in last five years. He has published more than thirty Research Papers in reputed International Journals. He has been the part of various National/ International Conferences in India and abroad, as a Paper presenter, Keynote Speaker, Technical Committee member & Technical Session Chair. He is the member of Reviewer board of various International Journals such as IJAMT-Springer, JIEI-Springer, ILT-Emerald, Journal of MaterialsSAGE etc. PUBLIC INTEREST STATEMENT During the machining of many soft engineering materials, formation of raised and rough edges, called “burrs”, are natural. This may cause many negative effects on the dimensional accuracy, shape and size of the final product. Therefore, removal of these formed burrs is extremely essential. For deburring the burrs formed in drilled holes, there are many conventional methods available but new innovation and efficient outlooks are always welcomed by engineers and are therefore needed for the better outcome; therefore the intervention of unconventional processes comes into picture in this area. The present research is all about deburring through Electric Discharge Machining process (EDM), in which machining was done with the help of electric discharge and deburring with EDM results into better surface finish as well as good automation. In this research some of the machining parameters are studied to analyses their effects on material removal rate, tool wear rate and burr removal. Received: 06 February 2016 Accepted: 02 December 2016 First Published: 26 December 2016 Page 2 of 19 © 2017 The Author(s). This open access article is distributed under a Creative Commons Attribution (CC-BY) 4.0 license.