Machinability study of Al 6063-based MMCs with SiC reinforcement particles using WEDM process

Sarmah, Pallab; Patowari, Promod Kumar

doi:10.1080/10426914.2022.2149786

Cited by 8 publications

(4 citation statements)

References 23 publications

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“…An electrolytic copper wire having diameter 0.25 mm is used as an electrode. The brass electrode wire converts the electrical energy to the thermal energy for the cutting materials like conductive ceramics, alloy steel and aerospace materials without the consideration of toughness and hardness of the material [24]. Deionised water acts as the medium of dielectrics, which possess rapid cooling rate with low viscosity.…”

Section: Wire Electrical Discharge Machining (Wedm)mentioning

confidence: 99%

“…Desirability function approach is also utilized in finding the optimal parametric combination for single-objective optimization together with multi-objective optimization. Optimization of the parameters of machining in WEDM based on desirability and statistical analysis concluded that the feed rate highly change on the MRR [23,24]. Verma et al employed desirability optimization to investigate various parameters.…”

Section: Introductionmentioning

confidence: 99%

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

Ramanan,

R R,

Suresh

et al. 2024

Mater. Res. Express

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This paper presents wire cut electrical discharge machining (WEDM) response characteristics of Aluminium 7075 (Al7075) reinforced with powdered activated carbon (PAC) composite. In recent days WEDM has become a significant machining process in targeting its benefits of contributing improved material removal rate (MRR) and low surface roughness (SR). This is due the rising need for intricate, accurate, and superior structural components, the WEDM process emerges as a formidable alternative to traditional machine tools. In this work Pulse-on time (Ton), pulse-off time (Toff), discharge current (IA) and servo speed rate (SS) are the variables to be given as input and machining responses such as MRR and SR are studied. From Analysis of Variance (ANOVA) study it is found that discharge current and servo speed is the significant parameters. The optimal desirability condition is obtained with input parameters Ip: 2000 mA; Ton: 8.9 µs; Toff: 25 µs and SS: 150rpm for the precision machining. The optimum response parameters are found as MRR 10.46 mm3/min and SR 3.32 µm. Results shows that the model designed for the prediction of MRR produces an above 98.27 % and the prediction of SR is above 97.17 %. The error percentage among the experimental and predicted MRR and SR were estimated. Additionally confirmatory test is performed with optimal results achieved from response surface methodology (RSM) and desirability technique. Metallurgical tests like electron backscatter diffraction analysis (EBSD) and microstructure are conducted to confirm the surface properties and atomic force morphology (AFM) analysis is applied to clarify the structural features of machined composites. The results revealed that the variation of hard deflection is caused by depression of eroded materials on the top layers of machined surface.

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Section: Wire Electrical Discharge Machining (Wedm)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

Ramanan,

R R,

Suresh

et al. 2024

Mater. Res. Express

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“…Silicon carbide particle reinforced aluminum matrix composites (SiCp/Al) find widespread applications in aerospace, optical instruments, and electronic devices due to their exceptional properties, including strength, stiffness, and wear resistance [1,2]. By incorporating the silicon carbide (SiC) particles into the aluminum matrix, the composite combines the lightweight and flexibility of aluminum with the hard-brittle characteristics of SiC [3,4], improving load-bearing capacity and wear resistance.…”

Section: Introductionmentioning

confidence: 99%

Photocatalytic-Assisted Electrochemical Machining of SiCp/Al: An Exploration of Mechanisms and Effects

Zhou,

Wang,

Wei

et al. 2024

Preprint

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Silicon carbide particle reinforced aluminum matrix composites (SiCp/Al), combine the properties of aluminum matrix materials and reinforced silicon carbide (SiC) particles, finding widespread application in aerospace, optics, and electronics. The increased hardness and electrochemical inertness of SiC particles present significant challenges in their processing. This research investigates the impact of photocatalytic processes on machining accuracy in electrochemical processing (ECM). The dissolution characteristics of SiCp/Al during ECM and photocatalytic-assisted electrochemical machining (PAECM) were analyzed with varying electrolyte compositions, using polarization curves and oxidation-reduction potential (ORP). Validation of improved machining accuracy in PAECM was achieved through no-feeding machining. PAECM, with its photocatalytic reactions, effectively blocked stray currents and stray corrosion, enhancing accuracy in profile creation. Comparative analysis revealed that PAECM exhibited smoother profiles and reduced Overcut Ratio (OCR) in hole and groove machining compared to ECM, particularly in groove machining. Adjusting machining gaps and reducing abrasive particle size in PAECM influenced groove depth and width, achieving optimal morphology with a 0.4 mm gap and a 2-3 nm abrasive particle size, resulting in a 370 μm depth.

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“…The considered parameter was pulse on and off time, Peak current. Pulse on have major influence on kerf width over others [5]. R.Calvo and M.Daniel conducted study on machining of high speed steel (HSS) AISI M42 in WEDM.…”

Section: Introductionmentioning

confidence: 99%

Investigation of wire EDM process parameter on kerf width for high chromium high carbon steel by response surface methodology

Gnanaprakasam¹,

Kumar²,

Siddiqui³

2023

World J. Adv. Eng. Technol. Sci.

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The current work focused on studying the effect of process parameter on kerf width in Wire EDM using molybdenum wire electrode. Pulse on time, pulse off time, Servo voltage and wire feed were selected as a process parameter for design the DoE in Response Surface Methodology. It was observed that electrical parameters chosen had a significant impact on the Kerf Width. Pulse on time is the most important electrical characteristic for Kerf Width. Higher duration of the spark causes the job to shift dimensions. Utilizing Design Expert's point prediction functionality, model validation was carried out.

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Machinability study of Al 6063-based MMCs with SiC reinforcement particles using WEDM process

Cited by 8 publications

References 23 publications

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

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

Photocatalytic-Assisted Electrochemical Machining of SiCp/Al: An Exploration of Mechanisms and Effects

Investigation of wire EDM process parameter on kerf width for high chromium high carbon steel by response surface methodology

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