Investigations on the influence of particle reinforcement and wire materials on the surface quality and machining characteristics of AA6061-TiB₂ alloy in WEDM

Abstract

In this research, the significance of particle reinforcement and the effect of wire materials on machining of AA6061-TiB 2 composite by Wire Electrical Discharge Machining (WEDM) was investigated. Stir cast AA6061-TiB 2 (varying 5, 10, and 15 wt.%) was used as the work material for this present study owing to its superior mechanical properties and profound applications. WEDM is the most viable cutting process to produce intricate shapes and sharp corners with good surface texture. Taguchi methodology was used to conduct the experiments. Phase constituents of the work material were observed using XRD analysis. The results revealed that aluminium and titanium diboride are the major phase constituents without any reaction phases. Metallographic analysis was conducted to figure out the erosion mechanism and crater formation during spark discharge. The experimentation reveals that the percentage of particle reinforcement was the dominating factor in surface quality (62.04%) and machinability (34.2%). The TiB 2 (5 wt.%) reinforced composite exhibits excellent machinability and surface quality. Furthermore, in terms of machining rate, zinc-coated brass wire performs better than plain brass wire. Contrastingly, plain brass wire exhibits superior surface quality. In addition to that multi-objective optimization was performed using desirability analysis to achieve higher material removal rate and lower surface roughness. After the confirmation test, it is seen that the experimental values are in close agreement with the estimated values.

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

“…According to results of multi-objective optimisation using the TOPSIS methodology, MRR and surface finish have improved while KW has significantly decreased. 3 Pulse on time, pulse off time, wire feed, wire tension, current and voltage [3] AA6061-TiB 2 Studied the effect of reinforcement and wire material on the surface roughness in MMCs.…”

Investigations on the effect of dielectric medium and WEDM parameters on surface characteristics of Al 7068 (ordnance aluminium) alloy

“…Consequently, intense diffusion processes occur amidst the machined surface and the wire electrode [34]. The formation of recast layer is owing to melting and re-solidification of molten chunks which is not flushed out by the dielectric medium [35]. The spark discharge causes superficial hardening in cut zones that changes the recast layer thickness.…”

Effect of Al7075 and activated carbon reinforced composite on optimizing WEDM responses

“…Ramraji et al highlighted the importance of particle reinforcement and explored the influence of wire materials on the machining of AA6061-TiB2 composite using Wire Electrical Discharge Machining (WEDM). The study investigated the use of stir cast AA6061-TiB2 with varying weight percentages of 5, 10, and 15% as the work material due to its exceptional mechanical properties and extensive applications [14]. The material gap constantly among the work piece and the wire that fluctuates between 0.025 mm and 0.05 mm.…”