Modelling and combined effect analysis of electric discharge Machining process using response surface methodology

Matharou, Gurpreet Singh; Bhuyan, Basanta Kumar

doi:10.1016/j.matpr.2021.04.103

Cited by 10 publications

(5 citation statements)

References 12 publications

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“…Wire EDM of Silicon Nitride -Titanium Nitride ceramic composite was developed based on central composite design method. Based on preliminary investigation, literature review and experience of machine operators, input parameters for twenty factorial trials were conducted (18) . The parameters that were selected for the input were pulse on-time (µs), short pulse duration (µs), and current (Ip).…”

Section: Design Of Experimentsmentioning

confidence: 99%

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Farooqui,

Patil,

Gore

2024

IJST

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Objective: To maximize the cutting rates and to minimize and width of cut (Kerf) by optimizing the process parameters for wire EDM machining of Si3N4-TiN ceramic composite utilizing zinc coated brass wire optimizing the process parameters by applying Response Surface Methodology using Central Composite Design Technique. Methods: The input parameters, namely, peak current, short pulse duration, and pulse on time duration were varied over five different levels, in order to conduct the studies. The distinctive response characteristics, such as cutting rates and width of cut, are investigated, and optimized using Response Surface Methodology (RSM), which is based on Design of Experiments (DOE). ANOVA was applied to both predictive modeling and the identification of significant variables in order to assess the effectiveness of the model. In the experiments, a coated brass wire electrode was employed in the center composite design. Findings: Comparing the cutting rates with a plain brass electrode, the increases are 4.39% and 16.67%, respectively. The pulse-on time and pulse current are recognized as the two most crucial input parameters; cutting rate rises with increasing current. A coated brass wire with negative tool polarity achieved a maximum cutting rate of 69.72 mm2/min at a peak current of 320A, 1.2 μs of on time pulse duration, the ideal Kerf of 0.35mm was obtained. The % error of RSM predicted and actual is 5.36% for cutting rate and 1.05% for Kerf. Novelty: There is no literature available on the machining of Si3N4-TiN using coated brass wire, for Kerf width and cutting speeds. The zinc-coated brass wire electrode improves the cutting rates and reduces the Kerf significantly for Si3N4-TiN ceramic composite. Keywords: Si3N4-TiN, CR, Kerf, RSM, ANOVA

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Section: Design Of Experimentsmentioning

confidence: 99%

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Farooqui,

Patil,

Gore

2024

IJST

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“…Table 4 (b) indicates the HMMC significant properties. The density of HMMC (2637 kg/m 3 ) as obtained through the test report has been used to calculate the MRR and EWR [20,21].…”

Section: Properties Of the Hmmcmentioning

confidence: 99%

Selection and Fabrication of HMMC (AL6063-SIC-B4C-MG)

Matharou¹,

Kaur²

2023

Recent Developments in Nanofibers Research

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This unit deals with the selection and fabrication of HMMC (Al6063-10SiC-5B4C-Mg) constituents by extensive biography review and satisfactory fabrication design. Researchers have promoted an extensive collection of Al6063 composites employing organic and inorganic reinforcements. The fundamental purpose of the broken-up stages is to constrain the metal matrix in a relevant capacity to strengthen the properties of the base materials. In the case of Al6063, the reinforcement weighty subject matter in the composite varies from 5 wt.% to 30 wt.%. Diverse classes of reinforcements had sought to integrate and operate in the composite formulation as hybrid reinforcements. This chapter further discusses the comprehensive development stages of 84% wt of Al 6063, 10% wt of SiC, 5% wt of B4C with 1% wt of Mg hybrid metal matrix composite (HMMC) through the stir casting approach. During the stir casting process, the melting action of the material emanates numerous gases and residuals apart from the expected composite. The residuals have numerous environmental concerns, which require discussion since some of the vapors and substantial waste can lead to detrimental effects on the environment in terms of air and soil pollution.

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“…It is clearly seen from the figure 7 that the micro cracks found on machined surface with best conditions are smaller in size compared to those occurring under worst conditions. This may be due to lesser time gap between the successive sparks in the machining region [35]. Usually, shorter gaps between sparks results in reduction in stress development and hence a reduction in micro cracks.…”

Section: Surface Morphologymentioning

confidence: 99%

“…They also studied the influence of tool materials with different geometry on output parameters and reported that the discharge current as a influencing parameter for MRR. Matharou et al [35] assessed the machinablity of HMMC in EDM under various levels of current, voltage and spark gap and pusle ON/OFF. They recommended the current as a effective parameter for MRR followed by voltage and spark gap.Yadav et al [36] demonstrated the machining characteristics of Al/SiC p /B 4 C p composite in EDG process at different machining condition.They also anlayzed the recast layer thickness and surface texture and concluded that the surface texture is clearly depends on current as compared to other parameters.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

Narasimmalu¹,

Ramabalan²

2022

Surf. Topogr.: Metrol. Prop.

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Al6063 composites are widely used in automobile, aerospace and biomedical industries due to their excellent mechanical properties. Machining of micro channels in composites is difficult for conventional machining process due to presence of hard reinforcement. Materials with base metal. Micro Electrical discharge (µED) milling is popular micromachining technique for machining simple, intricate shapes and microchannels on any conductive material. However, it a slow machining process, the identification of optimum condition has become wide research area in µEDM. The present work aims to study the influence of process variables namely voltage, spindle speed and threshold on machining characteristics of µED milling of Hybrid Metal Matrix Composites (HMMCs). Experimental trials are carried out with copper electrode at different parametric condition. Al6063-5%B4C-5%ZrSiO4 composite was fabricated using stir casting method and experimental runs were designed using general full factorial method. The significant parameters are identified using Analysis of Variance (ANOVA) and the ideal machining conditions for multi-response are determined using Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) method. The morphology of machined surface with best and worst conditions is examined using SEM. Results indicated that the voltage and threshold are the influencing parameters for considered response indicators. Recast layer thickness seems to be low with best machining conditions as compared to worst conditions. Increase in voltage and threshold increases the Material Removal Rate (MRR) and decreases the Electrode Wear Rate (EWR). Surface finish is better when the lower order of capacitance and voltage is used. MRR is increased by 48% with best machining conditions compared to worst machining condition.

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Modelling and combined effect analysis of electric discharge Machining process using response surface methodology

Cited by 10 publications

References 12 publications

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Selection and Fabrication of HMMC (AL6063-SIC-B4C-MG)

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

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Modelling and combined effect analysis of electric discharge Machining process using response surface methodology

Cited by 10 publications

References 12 publications

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

Selection and Fabrication of HMMC (AL6063-SIC-B4C-MG)

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO4 composite using TOPSIS method

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Product

Resources

About

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method