In this research work, an attempt was made to machine the titanium (Ti6Al4V) alloy utilizing electric discharge machining technique. The distinct process parameters and its impact on the machining performance were identified using the cause-and-effect diagram (CED). The key process parameters identified by CED diagram were current, pulse on time (Ton), aluminium oxide (Al2O3) powder concentration, and gap distance; experiments were conducted by varying the process parameters, experimental runs were designed using the Taguchi mixed orthogonal array. The experimental results revealed that improvement in material removal rate (MRR) was due to the bridging effect; reduction in tool wear rate (TWR) owing to the expansion of spark gap and enhancement in the surface roughness (Ra) was due to the complete flushing of machined debris. The interaction impact was analysed using the contour plot and with the aid of mathematical modelling experimental fits that were identified and the results were validated utilizing the sensitivity analysis. The obtained results were optimized using the technique for order of preference by similarity to ideal solution (TOPSIS) optimization technique.
The adoption of Aluminum Metal Matrix composites has gained popularity and widespread application in view of their light weight and superior mechanical strength compared to the un-reinforced alloy system. Much improved characteristics have been derived based on the adoption of secondary processes such as rolling, forming, drawing and plastic deformation. In this context, the preparation of Al2024 alloy, containing Beryl particles as reinforcement is envisaged for getting better properties in terms of strength and hardness for structural use in aerospace industry. Further enhancement in properties to strengthen the alloy may be possible by subjecting it to severe plastic deformation, especially Equal Channel Angular Pressing (ECAP) process. The present work focuses on developing Al 2024 alloy composites containing Beryl particles at 6 wt.%, through stir cast method. This is followed by ECAP process carried out in the annealed condition. This facility has been designed and developed in house. Following this, the mechanical properties, involving tensile strength, % elongation & hardness have been evaluated for the ECAP processed Al2024 Beryl samples and the values thus obtained are compared with those derived on samples without Beryl additions. The microstructures of the samples, for key stages of the work, have been recorded. Further, the fracture morphology of ECAP processed samples have been examined and analyzed using SEM/EDAX and correlated with the tensile strength data. The ECAP with pass II processed samples have shown higher tensile strength and hardness as well as good grain refinement in the matrix compared to annealed Al alloy sample.
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