Mild steel will be used in this study as the workpiece (roughly faced disc). It is the most commonly available of the cold-rolled steels. Mild steel is a type of plain carbon steel and is the most common steel used because its price is relatively low while providing good material properties for many applications such as structural works. Its carbon content 0.18% making it malleable, ductile and has relatively low tensile strength. Forgings, stampings, sheets and plates, bars, rods and tubes are made of mild steels. Chemically, Mild steel Alloy 1018 is very similar to A36 Hot Rolled steel, but the cold rolling process creates a better surface finish and better properties. [x]. Eagle steel. 2012. Low Carbon Steel. [ONLINE] Available at: http://www.eaglesteel.com/download/techdocs/Carbon_Steel_Grades.pdf. [Accessed 15 October 14]. Table 1.1 Physical properties of Mild steel Alloy 1018 [1]
Table 1.2 Chemical composition of Mild steel Alloy 1018 [1] Iron (Fe) 98.81 - 99.26% Carbon (C) 0.18% Manganese (Mn) 0.6-0.9% Phosphorus (P) 0.04% max Sulfur (S) 0.05% max Youngs Modulus (GPa) 210 Density (Mgm -3 ) 7.85 Yield Strength (MPa) 370 Ultimate Tensile Strength(MPa) 440 Poisson Ratio 0.29 Shear Modulus (GPa) 80 Rockwell Hardness B71 Melting Temperature ( o C) 1350 - 1530
Table 1.3 Electrical properties of Mild steel Alloy 1018
Electrical Properties at 0 o C
1.59 x 10 -5 -cm
Electrical Properties at 100 o C
2.19 x 10 -5 -cm
Electrical Properties at 200 o C
2.93 x 10 -5 -cm
Machine and Tool The whole experimental conducted on Electrochemical machining set up from the University of Mauritius. The experimental set up will consist of an electro machining unit and electrolysis tank. The electrolysis tank will be used to supply the electrolyte to the machining unit by the use of a pump. The electrolyte used will be sodium chloride (NaCl) with a concentration of 150g/l as described by D.Zhu et al. the voltage supplied will be 5.64V and a tool holding pressure of 61.0 KN/m described by S.C Tam and N.H Loh. Copper electrode will be used as an electrode through which the pressurized NaCl electrolyte will pass through described by M.A. Bejar and F. Gutierrez. The machine unit includes a spindle to insert the electrode. The maximum allowable current is set (60A) and the inter electrode gap accurately set such as 0.5mm, 0.9mm, 1.3mm, 1.7mm and 2.1mm . Afterwards the machining is done for a specific set of values. The machining performance of ECM depends majorly on: voltage, Current Density and inter electrode gap, and the machining time, t, will be set to 3 minutes. The surface roughness parameters that will be used to assess surface roughness of the workpieces are Ra, Rq, Rt, Rzdin, Ry and Sm described by A. K. M. De Sllva et al. It has to be noted that 5 workpieces will be used since it is an adequate size to draw out a good conclusion with minimum cost since data collection involved lot of money.
Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014: Analysis and Study of Control Factors on CNC-Wire Cut EDM for S7 Steel
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