Experimental investigation on the effect of SiC particles in machining process of Al–5.3%CU-SiCp–Al2O3p hybrid nanocomposite by EDM

Shabgard, Mohammad Reza; Zaki, Mohammad; Abbasi, H.

doi:10.1007/s42452-019-0401-z

Cited by 8 publications

(4 citation statements)

References 19 publications

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“…In the TWR's main effect plot, increasing the percent Sic nano particles in Al-based hybrid composite from 3 to 4.5 improves TWR, and then a dip is observed as shown in Figure 23. Shabgard et al [6] also discovered that increasing the reinforcing particles increases TWR. The increase in SiC particles will increase contamination and act as a barrier to electron movement between tool and workpiece.…”

Section: Effect Of Percent Sic Nano In Al-based Hybrid Compositementioning

confidence: 95%

“…The main effect plot of SR for experiment revealed that increasing the percent SiC nano particles in Al-based hybrid composite result in a decrease in SR from 3 percent to 4.5 percent, followed by an increase at 6 percent with the worst SR at 6 percent as shown in Figure 24. According to Shabgard et al [6] increasing the fraction of reinforcing particles in hybrid composite results in an increase in SR. Since SiC particles are ejected as solid when enough energy is provided due to their high melting point, the vacant space of each reinforcing particle will persist as a spot on the specimen's surface as shown in Figure 28.…”

Section: Effect Of Percent Sic Nano In Al-based Hybrid Compositementioning

confidence: 99%

“…The reason for the increase in MRR as the percentage of SiC nano particle increases in Al-based hybrid composite, is due to the fact that, lower energy is required for the ejection of nanoparticles from the base metal, compared to that of micro-sized particles. [6].…”

Section: Effect Of Percent Sic Nano In Al-based Hybrid Compositementioning

confidence: 99%

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Thermal modelling and Parametric optimization for Machining of Aluminum (Al-10%SiCmicro-SiCnano) based hybrid composite using Spark Erosion

Arif

Khan

Hasan

2023

Preprint

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In this study, the authors divided the work into two parts. The first part involved the development and validation of a thermal model for Electric Discharge Machining (EDM) using Ansys software. This model took into consideration various factors such as Gaussian heat flux, spark radius, fraction of heat transferred as a equation of pulse on time and pulse current, latent heat in specific heat values and temperature dependent thermal conductivity properties. Three different values of fraction of heat transferred to workpiece (Fc) were used in simulation to determine which one is better at correctly predicting MRR and SR. The second part involved the parametric study of the experimental results using ANOVA, main effect plot and grey relational analysis. The workpiece in this study was Al-based hybrid composites, which were manufactured using stir casting. Three composite materials, Al-10%SiCmicro-3%SiCnano, Al-10%SiCmicro-4.5%SiCnano, Al-10%SiCmicro-6%SiCnano were considered. The EDM process was accomplished using a L9 orthogonal array, and the performance parameters were measured in terms of MRR, TWR, SR, Dilation in hole diameter, and Hole taper. The results showed that the Fc value calculated using the Shabdard's function [1] provided the best prediction of MRR and SR, with a MRR ratio range of 1.20-8.00, followed by Fc taken from Dibitonto [2] (MRR ratio range -0.28-12.95) than Fc calculated from Ming et al. [3] (MRR ratio range 0-18.56). The results showed that the dilation in hole diameter and Hole taper increased with an increase in the percentage of SiC nano-particles, while TWR increased with an increase in the pulse current and Hole taper decreased with increase in pulse on time. The best EDM machining results were obtained at 6A pulse current, 20 pulse on time, and 6% SiC nano-particles in the hybrid composite. A validation experiment was also performed, and it was found that the MRR, dilation in hole diameter, and Hole taper improved at 6% SiC nano-particles, 6A pulse current, and 30 pulses on time.

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Section: Effect Of Percent Sic Nano In Al-based Hybrid Compositementioning

confidence: 95%

Section: Effect Of Percent Sic Nano In Al-based Hybrid Compositementioning

confidence: 99%

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Thermal modelling and Parametric optimization for Machining of Aluminum (Al-10%SiCmicro-SiCnano) based hybrid composite using Spark Erosion

Arif

Khan

Hasan

2023

Preprint

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“…For higher values of pulse on time, MRR and SR increased, whereas TWR decreased. 163 Jadam et al 164 studied the effect of peak current on MRR. As the peak current was increased, MRR increased for both conventional EDM and PMEDM as when peak current was increased; higher intensity sparks were generated.…”

Section: Surface Characteristicsmentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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Machining characteristics of various powder-based additives, dielectrics, and electrodes during EDM of micro-impressions: a comparative study

Ishfaq

Maqsood

Mahmood

2022

Int J Adv Manuf Technol

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Electric discharge machining (EDM) has great acceptance in different application sectors to wipe out intrinsic problems, like product miniaturizing and tight tolerances, during the fabrication of micro-size products. Many researchers have worked well in the micro-cutting of various alloys through the EDM process. However, limited work has been reported on the EDM of SS 316 for micro-impression fabrication using EDM. The selection of the best dielectric, electrode material, and powder-based additives has never been targeted so far to have dimensionally accurate micro-impression at an appreciable cutting rate with no/less electrode damage in the EDM of the said alloy. Therefore, in this research, the collective influence of various dielectrics (kerosene oil, transformer oil, and canola oil), powders (alumina, graphite, and silicon carbide), and electrodes (copper, brass, and aluminum) have been comprehensively examined for the fabrication of micro-impressions in AISI 316 using EDM. Taguchi L9 orthogonal technique was applied to study the effect of four input parameters on material removal rate, overcut, and tool wear rate. Results were statistically explored using main effect plots and supplemented by scanning electron microscopy, surface profilometry, and optical microscopy. The results show that material removal and tool wear rates notably improved from the mean value by 29% and 89.4%, respectively, when the machining is carried out under silicon carbide mixed kerosene dielectric against silicon carbide the aluminum tool at a pulse time ratio of 1.5. Furthermore, for dimensional overcut, 5.3 times lesser value is observed from the average magnitude of 0.189 mm when the proposed EDM setup is employed for cutting AISI 316. An optimized setting has also been proposed by grey relational analysis and then validated through a confirmation experiment.

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Experimental investigation on the effect of SiC particles in machining process of Al–5.3%CU-SiCp–Al2O3p hybrid nanocomposite by EDM

Cited by 8 publications

References 19 publications

Thermal modelling and Parametric optimization for Machining of Aluminum (Al-10%SiCmicro-SiCnano) based hybrid composite using Spark Erosion

Thermal modelling and Parametric optimization for Machining of Aluminum (Al-10%SiCmicro-SiCnano) based hybrid composite using Spark Erosion

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Machining characteristics of various powder-based additives, dielectrics, and electrodes during EDM of micro-impressions: a comparative study

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