The objective of the study is to predict the optimized set of the input parameters for the machining of non-conductive silicon carbide (SiC) by electric discharge machining (EDM). The insulated SiC ceramic composite machining was performed with 4 volumes (by percentage) of carbon nano (CNT) the SiC, which makes it electrically conductive. SiC has very good mechanical properties due to its widespread application in the aerospace, MEMS, and bio-sensor industries. This application requires a highly precise machining hole with a good surface quality that can be processed by machining processes such as EDM. The input parameters in this study are differing by three levels and the experimentation has been done by L27 orthogonal array. Four output parameters such as material removal rate (MRR), plasma flushing efficiency (PFE), surface-roughness (SR) and recast layer thickness (Rlt) for has been calculated for the detailed experimental analyses. In this research, a comparative analysis between the Multi-attribute management mechanisms (MADM) i.e. WPCA, MOORA & MOORA, and WPCA was conducted. The statistical analysis was also conducted to determine the impact of input parameters on performance measures. The study concluded that by integrating MOORA 's method with a PCA, the highest MRRs of 2.56 mm3/min & 78% PFE, lowest SR 2.1 µm, and Rlt 2.56 µm were obtained, with an experimental testing error of 5 percent.
Beryllium Copper (Be-Cu) alloy are advanced engineering alloy bearing high strength, high wear resistance, Corrosion resistance and nonmagnetic nature. These properties of Beryllium copper make it impossible to machining through Conventional machining process. Electrical Discharge machining (EDM) is a revolution to machine any type of harder material (Electrically conductive) without any physical pressure. EDM is best suitable to machine Be-Cu alloy for small holes and intricate shape used in heat exchanger. To know the best suitable input parameters for improving the machining efficiency of EDM numerical analysis is always required. In this study a mathematical modeling of Be-Cu alloy machined by EDM has been performed by finite element modeling (FEM) method. A 3D axi-symmetric computational domain has been considered for the analyses confined by proper boundary condition. The numerical simulation has been performed for single discharge machining. The model has been validated with the experimental results. Simultaneously the Material Removal Rate (MRR) has been calculated with varying Discharge Current (I) (8, 10, 12 A), Fractions of heat (Fc) (18 %, 20 %, 22 %) and Pulse On time (Ton) (100,150, 200 μS). The lowest error of 4.55 % (in MRR) between numerical model and experimental results has been determined at 10A current.
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