Investigation of the machinability of SiC reinforced MMC materials produced by molten metal stirring and conventional casting technique in die-sinking electrical discharge machine

Uğur, Abdullah; Nas, Engin; Gökkaya, Hasan

doi:10.1016/j.ijmecsci.2020.105875

Cited by 21 publications

(9 citation statements)

References 38 publications

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“…e lowest surface roughness and crater diameter values were determined at 2 amperes, 200 μs pulse time-on and 60 μs time-off, whereas the highest values were found at 600 μs pulse time-on and 20 μs time-off. It was determined that increased amperage and pulse duration affected the crater diameter and this situation adversely affected the surface roughness [22].…”

Section: Surface Roughness and Crater Diametermentioning

confidence: 99%

Experimental and Statistical Investigation of Machinability of AISI D2 Steel Using Electroerosion Machining Method in Different Machining Parameters

Nas

Özbek

Bayraktar³

et al. 2021

Advances in Materials Science and Engineering

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This study investigated the effects of machining parameters on the experimental and statistical results using the electric discharge method in the machining of AISI D2 cold work tool steel. The design of the experiment was established using the Taguchi L18 method. The effect of the experiment parameters on the performance characteristics was analyzed by analysis of variance (ANOVA). As a result of the study, it was determined that increasing amperage and pulse time affected the surface roughness and hole diameter on the surface of the material. The lowest values for surface roughness, machining time, hole diameter, and crater diameter were determined as 2.085 μm, 47 minutes, 12.010 mm, and 81.007 μm, respectively. The highest wear amount was obtained as 0.604 grams with the processed parameters in the ninth experiment. When the signal-to-noise ratios were examined, the optimum combinations of the control factors for surface roughness, hole diameter, crater diameter, wear amount, wear rate, and processing time were determined as A1B1C3, A1B1C3, A1B1C3, A1B3C1, A2B1C1, and A1B3C3, respectively. According to the ANOVA results, the most important parameters affecting the test results for surface roughness, hole diameter, crater diameter, wear amount, material wear loss, and processing time were determined as amperage (49.34%), time-on (59.38%), amperage (55.65%), time-on (56.92%), amperage (51.42%), and amperage (78.02%), respectively. When the gray relational degree was calculated for the maximum and minimum values, the ideal factors for all output results were found to be the parameters applied in the third experiment.

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Section: Surface Roughness and Crater Diametermentioning

confidence: 99%

Experimental and Statistical Investigation of Machinability of AISI D2 Steel Using Electroerosion Machining Method in Different Machining Parameters

Nas

Özbek

Bayraktar³

et al. 2021

Advances in Materials Science and Engineering

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“…The machined hole diameter and roughness were observed to increase with an increase in pulse-on time and current during the sinker EDM of AA7075-SiC composite. 36 Because the EDM processing conditions had a significant influence on the performance characteristics, which are multiobjective for a given work and tool electrode combination, proper planning of experimentation and analysis tools are required to get the optimum levels of process parameters. Moreover, it is highly recommended for novel materials like composites and functionally graded materials.…”

Section: Electro-discharge Machining Of Compositesmentioning

confidence: 99%

“…The various MMCs were studied for machinability via several EDM invariants such as wire EDM, 22–2324252627282930 sinker EDM, 3132333435363738 ED grinding, 39 rotary EDM, 8 ultrasonic EDM, 40 powder-mixed EDM, 41, 42 magnetic field–assisted EDM, 25 hybrid EDM, 43 magnetorheological fluid–assisted EDM, 44 micro-EDM, 45 etc. It was observed that the crater size is proportional to the discharge energy with relatively less surface damage of Al-SiC composite in EDM as compared to laser machining and abrasive water-jet machining.…”

Section: Introductionmentioning

confidence: 99%

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A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

Gudipudi¹,

Selvaraj

Subbu

et al. 2021

Journal of Micromanufacturing

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In electro-discharge machining (EDM), the material removal takes place by precisely controlled sparks that occur between tool and workpiece separated with a spark gap in the presence of a dielectric. Generally, the non-contacting type and less material removal rates are attributed to attain a good surface finish and close dimensional tolerances during an EDM of monolithic metals and alloys. But the dimensional accuracy and surface integrity parameters would considerably affect during EDM of composites due to the existence of more than one material phase constituents. Therefore, the present work aims to study and optimize the performance characteristics under various EDM conditions employed in making rectangular channels on AA6061-B4C composite material. Initially, AA6061-4wt.%B4C composites were fabricated by ultrasonically assisted stir-casting, and the improved properties were obtained from various mechanical characterizations. The EDM experiments were conducted according to the full factorial experimental design. The three levels of input conditions such as discharge Current (I), discharge duration (T On), and discharge idle time (T Off) were considered. The considered output responses are material removal rate (MRR),taper (θ) of the machined channel, tool wear rate (TWR), average surface roughness (R) of the machined surface, and average recast layer thickness (ARLT) of the machined zone. These responses are co-related with multi-objective types in the sense that the MRR has to be maximized with all other responses minimized. Hence, principal component analysis (PCA) coupled with grey relation analysis (GRA) was used for optimization in which the results were normalized, and all the responses were converted into a single response named weighted grey relation grade (WGRG) for each trial. The experimental trial, which had the highest WGRG, was considered as a local optimum. The global optimum parameters were obtained by performing the Taguchi method (TM) (higher-the-better) for the maximization of WGRG. The analysis of variance (ANOVA) was performed to know the contribution of each EDM parameter toward the WGRG. The optimum levels of Current, T On, and T Off were identified as 8 A, 25 µs, and 36 µs, respectively. Results showed that all three input parameters significantly affected the WGRG, and a higher contribution of Current (52.11%) followed by the T On (26.72%) was observed. The interaction between the Current and T Off was found to be greater than other interactions. Taper values were observed to be reduced at the combination of 8 A discharge Current and 25 µs T On. None of the input parameters significantly affected the Ra, except for Current, which showed a slight effect. ARLT values showed an increasing trend of T On from 25 µs to 45 µs but decreased slightly at 65 µs for all Current levels. The moderate Current level 6 A was observed to be favorable in reducing ARLT when compared to low (4 A) and high (8 A) for all Ton values.

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“…It is also difficult to produce complex contour through conventional machining. In such situations, electrical discharge machining (EDM) can be a substitute to the conventional machining, as there is no negative aspects like mechanical stress, chatter or vibration that likely affect the machining performance adversely [16].…”

Section: Introductionmentioning

confidence: 99%

Machinability and surface morphology investigations of multiwall carbon nanotube reinforced aluminium 7075 metal matrix composite during electrical discharge machining: A grey relational approach

Pradhan,

Tripathy,

Prasad

et al. 2023

Materialwissenschaft Werkst

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Multiwall carbon nanotube buttressed aluminium 7075 metal matrix composite was synthesized through an amended liquid metallurgy method, which consisted semisolid stirring, ultrasonic treatment and squeeze casting. Aim was to investigate its machinability and surface morphology during electrical discharge machining. Variable machining factors were peak current, pulse‐on time and gap voltage, whereas the responses under investigation were electrode wear rate, material removal rate and average surface roughness. Results revealed electrode wear rate, material wear rate and average surface roughness increased on increasing peak current and pulse‐on time, but all these responses behaved inversely with the increase of gap voltage. Average surface roughness reduced by around 44 % on reducing the peak current from 10 A to 4 A and increasing gap voltage from 55 V to 80 V at constant pulse‐on time of 300 μs; however, it increased by around 25 % on reducing the gap voltage from 80 V to 55 V and increasing the pulse‐on time from 100 μs to 300 μs at constant peak current of 10 A. Significance of the process parameters were verified, regression models were developed and morphology of the machined surfaces was studied. Finally, multiple response optimization was conducted following grey relational approach.

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Investigation of the machinability of SiC reinforced MMC materials produced by molten metal stirring and conventional casting technique in die-sinking electrical discharge machine

Cited by 21 publications

References 38 publications

Experimental and Statistical Investigation of Machinability of AISI D2 Steel Using Electroerosion Machining Method in Different Machining Parameters

Experimental and Statistical Investigation of Machinability of AISI D2 Steel Using Electroerosion Machining Method in Different Machining Parameters

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

Machinability and surface morphology investigations of multiwall carbon nanotube reinforced aluminium 7075 metal matrix composite during electrical discharge machining: A grey relational approach

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