A comprehensive investigation of geometrical accuracy errors during WEDM of Al6061-7.5%SiC composite

Ishfaq, Kashif; Farooq, Muhammad Umar; Anwar, Saqib; Ali, Mohammad; El-Sherbeeny, Ahmed M.

doi:10.1080/10426914.2020.1832683

Cited by 30 publications

(20 citation statements)

References 32 publications

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“…Various optimizations techniques such as Taguchi, Principal Component Analysis, Fuzzy Logic, Particle Swarm Analysis, RSM, and other statistical tools have been implemented by the researchers during turning of HSLA [30]. But RSM is considered as the one of the best modeling approaches in designing, developing, and improvement of a process, a product design [34]. RSM provides robust design of experiments and empirical modeling with superior confidence interval which not only saves time and cost of experimentation but also supports machinists achieving desired outcomes.…”

Section: Methodsmentioning

confidence: 99%

“…This technique is employed to allocate the desirability range from 0 to 1 (minimum to maximum); which depends on the envisioned responses, incase to minimize or maximize the targeted response. Firstly, desirability function is established, after that, objective function, as well as compound function, are determined that is weighted geometric mean for all responses values [34]. 9.…”

Section: One-step Sustainabilitymentioning

confidence: 99%

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Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Javid

Jahanzaib

Jawad

et al. 2021

Int J Adv Manuf Technol

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The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, the focus is shifted towards sustainable and cleaner machining processes. Besides the clean technologies, effective parametric control is required for machining materials (such as High Strength Low Alloy Steels) specifically designed for high strength applications having superior physio-chemical properties. Therefore, the machinability complexities require optimized solutions to reduce temperature elevation and tooling costs and improve machining of these materials. Complying to the market needs, this research examines the effectiveness of nanofluid on tool life, wear mechanisms, surface roughness (Ra), surface morphology, and material removal rate (MRR) in turning of 30CrMnSiA (HSLA) using minimum quantity lubrication (MQL) and SiO2-H2O nanofluids (NF-MQL). A systematic investigation based on physical phenomena involved is carried out considering four process parameters (cutting speed (VC), feed rate (Fr), depth of cut (DOC), and mode of lubrication for machining. Fr is found as the vital parameter for surface roughness while MRR is highly influenced by DOC regardless of lubrication approach. One-step sustainability technique is applied, in which process variables used for roughing conditions are analogous to attain surface comparable to finished machining without compromising process efficiency and demonstrate its feasibility through optimal settings under NF-MQL. Multi-response optimization proved the NF-MQL machining condition as the best alternative which result in 28.34% and 5.09% improvements for surface roughness and MRR, respectively. Moreover, the use of SiO2 is recommended over MQL due to lower energy consumption, low tool wear, and better surface integrity, sustainable liquid, and related costs.

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Section: Methodsmentioning

confidence: 99%

Section: One-step Sustainabilitymentioning

confidence: 99%

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Javid

Jahanzaib

Jawad

et al. 2021

Int J Adv Manuf Technol

Self Cite

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“…The white layer is produced during machining when the leftover melt material resolidifies on the machined surface of the workpiece [41]. Therefore, the recast layer thickness plays a vital role in evaluating the surface integrity of the machined specimen.…”

Section: Effects Of Pulse-on Durationmentioning

confidence: 99%

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Khan

Rehman

Farooq

et al. 2021

Metals

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Recently, DC53 die steel was introduced to the die and mold industry because of its excellent characteristics i.e., very good machinability and better engineering properties. DC53 demonstrates a strong capability to retain a near-net shape profile of the die, which is a very challenging process with materials. To produce complex and accurate die features, the use of the wire electric discharge machining (WEDM) process takes the lead in the manufacturing industry. However, the challenge is to understand the physical science of the process to improve surface features and service properties. In this study, a detailed yet systematic evaluation of process parameters investigation is made on the influence of a wire feed, pulse on duration, open voltage, and servo voltage on the productivity (material removal rate) and material quality (surface roughness, recast layer thickness, kerf width) against the requirements of mechanical-tooling industry. Based on parametric exploration, wire feed was found the most influential parameter on kerf width: KW (45.64%), pulse on time on surface roughness: SR (84.83%), open voltage on material removal rate: MRR (49.07%) and recast layer thickness: RLT (52.06%). Also, the optimized process parameters resulted in 1.710 µm SR, 10.367 mm3/min MRR, 0.327 mm KW, and 10.443 µm RLT. Moreover, the evolution of surface features and process complexities are thoroughly discussed based on the involved physical science. The recast layer, often considered as a process limitation, was explored with the aim of minimizing the layers’ depth, as well as the recast layer and heat-affected zone. The research provides regression models based on thorough investigation to support machinists for achieving required features.

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“…The work also identified that the increase in the percentage of SiC led to lower surface finish. Ishfaq et al [27] targeted his work on wire EDM machining of Al6061-7.5% SiC composite. The work aimed at optimizing the kerf width, surface roughness, and cutting rate of the based on the input parameters of current, voltage, and pulse-on-time.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Kerf Width and Surface Roughness of Al6351 Based Composite in Wire-Cut Electric Discharge Machining Using Mathematical Modelling

et al. 2022

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The machining of composite materials has been an area of intense research for the past couple of decades due to its wide range of applications, from automobiles to air crafts or from boats to nuclear systems. Non-conventional machining, especially electric discharge machining (EDM), is found to be a good machining option for meeting the required outputs. To overcome the challenges of machining complex shapes, wire electric discharge machining (WEDM) was developed. Al6351 composites was observed to be extensively used in nuclear applications. Therefore, identifying the kerf width and surface roughness are important criteria for the dimensional accuracy of the final product. The present work aims at predicting the behavior of the two major machining parameters which are kerf width and surface roughness of Al6351 composites in wire EDM by creating a mathematical model using ANOVA for different combinations of the reinforcements and comparing the variations in the coefficients for different combinations of reinforcements. The developed model has been validated by conducting similar set of experiments in Al6351-5% SiC-1% B4C hybrid composite. From the work, it was identified that pulse on time and current are the major contributing factor for kerf width and wire feed rate was observed to be contributing to the surface roughness. The validation results show an average variation of 8.17% for kerf width and 11.27% for surface roughness. The work can be successfully utilized for prediction of the kerf width and surface roughness of the composites manufactured with Al6351 as the base matrix material.

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A comprehensive investigation of geometrical accuracy errors during WEDM of Al6061-7.5%SiC composite

Cited by 30 publications

References 32 publications

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Prediction of Kerf Width and Surface Roughness of Al6351 Based Composite in Wire-Cut Electric Discharge Machining Using Mathematical Modelling

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