Surface Integrity Associated with SiC/Al Particulate Composite by Micro-Wire Electrical Discharge Machining

Wang, Zhenlong; Geng, Xiurui; Chi, Guanxin; Wang, Yukui

doi:10.1080/10426914.2014.901520

Cited by 35 publications

(13 citation statements)

References 19 publications

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“…The surface of SiCp reinforced Al6061 MMC after machining by WEDM is full of micro-pores, shallow holes, micro-fissures, and drops of debris [42]. Thus distinct difference on the appearance of the machined surfaces for different machining condition is not apparent.…”

Section: Resultsmentioning

confidence: 98%

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Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

Pramanik

2015

Materials and Manufacturing Processes

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This paper investigates material removal rate (MRR), kerf width, surface finish and electrode wire wear for different pule-on-times as well as wire tensions during EDM of 6061 aluminium alloy reinforced with 10 vol% 700 nm SiCp MMC. Effects of pulse-ontime on output variables at lower and higher wire tensions were investigated. Similarly, effects of the wire tensions on output variables at shorter and longer pulse-on-times were also investigated. Longer pule-on-time increases the MRR though the higher wire tension reduces the MMR. The effect of wire tension on MRR is much more significant at longer pule-on-time compare to that at shorter pule-on-time. There is an optimum pule-on-time for which best surface finish is achieved. The surface finish deteriorates when the pulseon-time is higher or lower than the optimum pule-on-time. With the rise of tension in wire, the surface roughness increases and decreases at shorter and longer pule-on-times respectively. The machined surface contains solidified molten material, splash of materials and blisters. Generation of the tapered slot with higher kerf width at the top indicates the wear of wire electrode. Significant variation of the electrode wire diameter was due to coating of the matrix, wear and clogging of small reinforced particles in the electrode gap.

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Section: Resultsmentioning

confidence: 98%

“…The harder touch of the wire at higher tension with higher energy generates smoother surface. A multi-cutting arrangement where first cutting and finish cutting are performed sequentially, can be used to reduce the surface roughness to the fraction of a micron [42].…”

Section: Resultsmentioning

confidence: 99%

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

Pramanik

2015

Materials and Manufacturing Processes

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“…AFM is a state-of-the-art finishing / polishing process for the products of intricate shapes, internal sections, the intersection of holes, slots, concave or convex edges, etc., [2]. Accelerating the abrasion medium formed by abrasive particles in a polymer to carry it into channels along with oil for maintaining the viscosity increases the material removal rate (MRR) and surface finish (Ra) [3].…”

Section: Introductionmentioning

confidence: 99%

Genetic Based Experimental Investigation on Finishing Characteristics of AlSiCp-MMC by Abrasive Flow Machining

Yunus

Alsoufi

2020

Int. j. eng. technol. innov.

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Implementing non-conventional finishing methods in the aircraft industry by the abrasive flow machining (AFM) process depends on the production quality at optimal conditions. The optimal set of the process variables in metal-matrix-composite (MMC) for a varying reinforcement percentage removes the obstructions and errors in the AFM process. In order to achieve this objective, the resultant output functions of the overall process using every clustering level of variables in a model are configured by using genetic programming (GP). These functions forecast the data to vary the percent of silicon carbide particles (particles without experimentation obtaining the output functions for material removing rates and surface roughness changes of Al-MMCs machined with the AFM process by using GP. The obtained genetic optimal global models are simulated and, the results show a higher degree of accuracy up to 99.97% as compared to the other modeling techniques.

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“…This cutting speed varies for different materials with respect to its conductivity and material property. In order to study the coated brass wire performance in WEDM, many researchers used this wire to machine materials such as Udimet 720, AISI 4140 steel, titanium alloy and aluminium metal matrix composites [19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Machining of Ti–6Al–4V using diffusion annealed zinc-coated brass wire in WEDHT

Vignesh

Ramanujam

2019

J Braz. Soc. Mech. Sci. Eng.

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Titanium is predominantly used in the industrial sectors such as bio-medical, chemical, aircraft and marine because of its improved properties such as corrosion resistance and strength. Other properties such as increased toughness, hardness, poor thermal diffusivity make the material to fall under the category of difficult-to-cut, and this gave rise to the introduction of advanced machining processes. Wire electrical discharge hybrid turning (WEDHT) is one such process which could machine electrically conductive material and is discussed in this present research work. WEDHT of Ti-6Al-4V alloy is performed with diffusion annealed zinc-coated wires in the presence of deionised water as the dielectrics. The objective of the present work is to analyse the quality of the machined surface and the amount of material removed during hybrid turning process. The input parameters chosen for the present experimentation are wire feed rate (3, 4, 5 m/min), pulse ON time (108, 111, 114 µs), servo feed (5, 7, 9 mm/min), to conduct 27 experiments. The surface quality of the machined component is studied and analysed using 2D and 3D surface profilers along with scanning electron microscopic images. The effect of heat on the machined sample and its effect on the work material surface are studied with the help of micro-hardness analysis. The amount of material removed is calculated by measuring the weight of the sample prior to and after machining. From experimentation, the lower surface roughness of 2.0087 µm is obtained at 108 µs of pulse ON time, 5 m/min of wire feed rate and 5 mm/min of servo feed. The increased material removal 0.0169 g/min is obtained at 114 µs of pulse ON time, 5 m/min of wire feed rate and 5 mm/min of servo feed. On comparison, diffusion annealed zinc-coated brass wires outperformed uncoated brass wires with 18.95% and 44.37% for surface roughness and material removal rate criteria, respectively.

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Surface Integrity Associated with SiC/Al Particulate Composite by Micro-Wire Electrical Discharge Machining

Cited by 35 publications

References 19 publications

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

Genetic Based Experimental Investigation on Finishing Characteristics of AlSiCp-MMC by Abrasive Flow Machining

Machining of Ti–6Al–4V using diffusion annealed zinc-coated brass wire in WEDHT

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