Optimization of Wire EDM Process Parameters for Machining Hybrid Composites (356/B4C/Fly Ash) using Taguchi Technique

Prakash, J. Udaya; Juliyana, S. Jebarose; Pallavi, Pooja; Moorthy, T.V.

doi:10.1016/j.matpr.2017.11.395

Cited by 35 publications

(13 citation statements)

References 11 publications

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“…This energy introduces a localized heat flux into the target surface that causes strong melting and vaporization of the work surface. Thus, deep craters are formed at the machined surface, which give rise to the roughness of the machined surface [25,26]. This has also been Fig.…”

Section: Surface Roughnessmentioning

confidence: 75%

“…They observed that at a higher value of current and pulse on time, high instantaneous energy was released that caused the enhanced melting of the base metal matrix and deteriorated the machined surface. Prakash et al [25] found that voltage (66.27%) and pulse on time (18.74%) prominently influenced the cutting rate during the WEDM of 356/B4C/ fly ash composite. In another research work [26], it was established that higher current leads to high thermal melting of material by generating large size crater on the machined surface of AMC that reduced the surface quality.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Ishfaq

Anwar

Ali

et al. 2020

Int J Adv Manuf Technol

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The emerging demands of industry for developing the novel materials with superior mechanical properties have successfully resulted in the development of distinct materials such as Al-matrix composites. Among these composites, newly developed Al6061-7.5% SiC holds promising mechanical characteristics. But, the SiC reinforcement in the Al-matrix makes the machining of this composite challenging, thus posing a serious concern regarding its effective utilization. In this research, high-speed wire electric discharge machining (WEDM) was employed for the precise machining of a squeeze casted Al6061-7.5% SiC composite. The cutting performance of the WEDM was assessed in terms of roughness (SR), cutting rate (Cs) and kerf width (KW). Experimentation was performed according to the response surface methodology. The experimental findings were thoroughly investigated using statistical, optical and scanning electron microscopic (SEM) analyses. It has been revealed that the voltage is most influential/contributing parameter (having a percentage contribution of 25%) for controlling the SR during WEDM of Al6061-7.5% SiC composite, whereas for the CS and KW, pulse and current are the major contributing control variables with percentage contributions of 90% and 84%, respectively. At low magnitude of both current and voltages, the surface quality is improved up to 33.3%. The SEM and optical microscopic evidences reveal shallow craters, small size melt re-deposits and micro globules on the machined surface at lower settings of both the said variables. Contrarily, for achieving higher cutting speed, high values of current and voltage along with low pulse are deemed essential. In case of KW, low magnitude of current and voltage along with smaller pulse yields 20% reduction in the kerf width. The analyses revealed the conflicting nature of the studied output responses (SR, Cs and KW). Therefore, multi-objective genetic algorithm (MOGA) was used to find a parametric combination. The best combination of WEDM input parameters found is current = 3 A, voltage = 84.999 V and pulse = 10 mu. This combination gives a minimum SR of 5.775 μm with a KW of 0.3111 mm at a CS of 5.885 mm/min. The suitability of the MOGA-proposed parametric combination was witnessed through confirmation trials. Furthermore, the parametric effects have also been mathematically quantified with respect to the defined machinability parameters.

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Section: Surface Roughnessmentioning

confidence: 75%

Section: Introductionmentioning

confidence: 99%

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Ishfaq

Anwar

Ali

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

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“…Kumar et al, [24] employed Al6351/SiC/B4C hybrid AMC prepared by stir casting technique for the parametric optimization in the WEDM process. Their findings revealed that concentration of boron carbide particles has a significant impact on SR. Prakash et al, [25] examined the influence of V, TON, TOFF, FR, and concentration of two distinct reinforced particles on material removal rate of Al356/B4C/fly-ash hybrid AMC manufactured by the stir casting process. Their results declared that V and TON have considerable impact and concentration of reinforced particles has a negligible effect on material removal rate.…”

Section: Introductionmentioning

confidence: 99%

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

Raza

Ali

Tahir

et al. 2021

Preprint

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Increasing demand for aluminum matrix composites (AMCs) in the manufacturing sector leads to the development of squeeze casted hybrid AMCs bearing superior mechanical attributes. Excessive hardness due to squeeze pressure and the presence of reinforcement particles makes the machining of AMCs challenging and results in excessive tool wear and inadequate surface finish. Wire electric discharge machining (WEDM) process has been preferred over conventional manufacturing processes for the machining of squeeze casted Al2024/Al2O3/W hybrid composite. This study investigates the selection of the most pertinent wire electrode for the precise machining of Al2024/Al2O3/W. Simple zinc-coated (NT) and cryogenic treated (CT) brass wire electrodes have been selected for machining. Scanning electron microscope (SEM) analysis of CT wire shows that cryogenic treatment enhances the soundness and stability by reducing microcavities in its microstructure. To analyze the effects of cryogenic treatment, the machining performance of CT wire has been compared with NT wire. Besides wire type, the influence of key input variables has also been analyzed on the imperative response measures including cutting speed (CS), surface roughness (SR) and kerf width (KW) to make the machining process more effective. Microstructural analysis of NT wire depicts a high concentration of micro-voids, micro-cracks, and deep craters, while the surface of CT has been observed relatively fine after the machining. Comparative analysis of both wire electrodes has declared that CT wire yields 26.96% and 15.10% superior results for CS and SR respectively, and 6.92% deprived results for KW than NT wire.

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“…This process is carried out by methods of mechanical mixing and hardening of the liquefy [3]. Fly ash has become a matter of concern among the scientists due to its low density [4]. In the final stage of processing, drilling is put through, and these drilled holes are considered as stress concentration locations.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Machining Parameters in Drilling of Aluminum Matrix Composites (LM6/Fly Ash) utilizing Taguchi Technique

Rubi*,

Prakash

2019

IJITEE

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The present study revolves around the possibility of setting machining parameters in the drilling of composites of aluminum matrix (LM6/Fly ash) using the signal to noise ratio analysis. The aim of this work is to consider, the impact of input parameters, feed, speed, drill and percentage of composite material reinforcement on thrust force during AMCs drilling. AMCs were manufactured by the stir casting process with LM6 aluminium alloy as matrix material and fly ash as reinforcement material. Investigations were directed on a CNC vertical machining center for estimating thrust force. The Taguchi strategy for trial configuration is a generally admitted system employed for delivering great items requiring less effort. In the same way, L27 orthogonal array is employed for the analyses. The response table, graphs and variance analyzes are used to demonstrate the potential environment and the effects of machining parameters. It is evident that there is a tremendous improvement in the drilling procedure by using this methodology.

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Optimization of Wire EDM Process Parameters for Machining Hybrid Composites (356/B4C/Fly Ash) using Taguchi Technique

Cited by 35 publications

References 11 publications

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

Optimization of Machining Parameters in Drilling of Aluminum Matrix Composites (LM6/Fly Ash) utilizing Taguchi Technique

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