Several components are made from Al-Mg-based composites. MoS2 is used to increase the composite’s machinability. Different weight percent (3, 4, and 5) of MoS2 are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS2 composite. The machined surface’s roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I3, Ton2, and V1 are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.
Ceramic materials that find their applications in die extrusion and the balls used in bearings have a longer service life compared to that of traditional materials. Since ceramic materials are having high hardness properties, they cannot be machined traditionally, because traditional machining processes rely on the relative hardness of the tool material to the workpiece material. However, electric discharge machining aids in the machining of ceramic composites with good surface integrity performed by the copper electrodes. As a result, Spark Erosion Machining was used to investigate the geometrical tolerance of Si3N4-TiN composites. Electric discharge machining parameters range over five levels, like current from 2 to 6 A, voltage from 30 to 50 V, dielectric pressure (kg/cm2) from 16 to 24 kg/cm2, pulse on time (µs) from 15 to 19 μs, and pulse off time (µs) from 7 to 11 μs have been analyzed through an L25 orthogonal array. Main effect plots and two-dimensional and three-dimensional interaction plots have been drawn to investigate the effect of the input parameter on the output parameters like circularity, cylindricity, perpendicularity, runout, top radial overcut, and bottom radial overcut. The grey relational analysis is employed in finding the significant parameters through analysis of variance, and for each model, the regression coefficient is found. The optimal input parameters for the desired output parameters are found to be a current of 5.855 A; pulse-on time of 16.55 µs; pulse-off time of 7.22 µs; dielectric pressure of 16.32 kg/cm2; and a voltage of 40.3729 V. This research will help to enhance the geometric accuracy and precision of machined holes in Si3N4-TiN composites. The results are finally estimated using a residual data analysis, which shows that spark erosion can be improved.
The present research work exhibits the effect of reinforcement particles on the mechanical and wear properties of AA4032 hybrid and unhybrid metal matrix composites (MMCs). The unhybrid MMCs were prepared by incorporating titanium carbide (TiC) particles onto the AA4032, whereas the hybrid MMCs were prepared by the addition of hexagonal boron nitride (h-BN) particles to unhybrid AA4032-TiC composite. The tribological study conducted on the composites reveals that the wear rate was augmented at a higher applied load because of the formation of plastic deformation with some cracks. The generation of shear stress at an elevated applied load increases the coefficient of friction (COF). However, the addition of TiC and h-BN particles decreases the COF and wear rate because of the abrasion resistance and self-lubrication property of TiC and h-BN, respectively. The wear mechanism map study confirms that the hybrid MMCs have better wear resistance properties than the unhybrid MMCs with minimum delamination.
Metal matrix composites (MMCs) give challenges during machining because of the reinforcements present in them as this ultimately leads to increased tool wear and a poor surface finish. Considering this, Al-Mg-MoS2 composite samples prepared using powder metallurgy process are employed under unconventional machining process like wire electrical discharge machining (WEDM), since the composites prepared to possess a higher hardness and strength compared to that of pure aluminium. The machining is done under 3 different factors operated at 3 levels, peak current (10A, 15A & 20A), pulse on time (60µs, 90µs & 120µs), and gap voltage (40V, 45V & 50V) to analyze the material removal rate (MRR), surface roughness (SR) and overcut (OC). The surface texture of the machined samples is analyzed with scanning electron microscopy (SEM) and the recast layer so formed has also been analyzed. It is detected that the recast layer is found larger for larger surface roughness due to the higher spark energy at high-level peak current. Also, an optimal parameter of 15A peak current, 45V gap voltage and 90µs pulse on time and 4 % of MoS2 is determined through main effect plots for better machinability of the samples to obtain a better MRR, SR and OC. A better MRR, an improved surface finish and a reduced OC is seen in Al - 4%Mg - xMoS2 composite samples than that of pure Al and Al - 4% Mg materials.
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