Optimization of process variables on Electrical Discharge Machining of novel Al7010/B4C/BN hybrid metal matrix nanocomposite (original) (raw)
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E3S Web of Conferences
In this paper, determination of optimum EDM input variables like discharge current (DC), pulse on time (Pon), pulse off time (Poff), and gap voltage (GV) on responses like material removal rate (MRR) and surface roughness (SR) using Taguchi technique on the novel Al7010/2%B4C/2%BN hybrid metal matrix nanocomposite (HMMNC) manufactured through ultrasonic assisted stir casting (UASC) route. The various experiments were planned and carried out L16 orthogonal array and regression equations were established by using Analysis of variance (ANOVA) to examine the impact of pulse factors. The outcomes exposed that discharge current greatest effect factor on MRR and SR was found with % contribution of 82.07% and 86.86%. It is also identified that the optimum level conditions of pulse factors for MRR and SR is A4B4C1D1 and A1B1C4D4. The outcomes were further determined by utilizing confirmatory experiment. The machined surface morphology was observed through Scanning electron microscope (SEM).
INFLUENCE OF EDM PROCESS PARAMETERS OF NOVEL Al7010/B4C/BN HYBRID METAL MATRIX NANOCOMPOSITE
Composites Theory And Practice, 2023
In this present research work, the electrical discharge machining (EDM) characteristics of an Al7010/2%B4C/2%BN (the reinforcement particles are taken as wt.%) hybrid metal matrix nanocomposite (HMMNC) are discussed. The effect of the EDM process variables like the discharge current (I), pulse on time (Pon), pulse off time (Poff) and gap voltage (Vg) on the response characteristics like the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) are presented. The results revealed that the MRR, TWR, and SR grew with an increase in Ip and Pon. MRR, TWR, and SR increased with a rise in Poff up to 25 µs then declined. MRR, TWR, and SR decreased with an increment in gap voltage. The highest MRR was observed for a discharge current of 8 A, Pon of 60 µs, Poff of 25 µs and Vg of 30 V. SR and TWR were the smallest at Ip of 2 A, Pon of 15 µs, Poff of 55 µs and Vg of 60 V. The scanning electron microscope (SEM) micrographs of the machined surfaces revealed voids, craters and micro cracks.
Advances in Materials Science and Engineering
Electrical discharge machining (EDM) is a cost-effective unconventional machining method used for machining any composites materials. EDM is based on the thermoelectric energy between the electrode and workpiece. In this work, boron carbide particles of 50 nm (6 wt.%) are reinforced with aluminum 7075 (94 wt.%) prepared using stir casting method. The stir casting process is carried out at speed of 700–800 rev/min. The fabricated aluminum-boron carbide nanometal matrix composites are used as workpiece (anode); copper electrode is used as tool (cathode). This work investigates the influence of EDM process parameters such as current (I), pulse on-time (ton), and tool diameter (d) during machining of Al-B4C composite on metal removal rate (MRR) and tool wear rate (TWR). The design of experimental plan is executed by Taguchi approach, and the responses of each parameter are influenced by analysis of variances (ANOVA). Response table for average value of MRR and TWR shows that the current...
This study investigates the effect of electric discharge machining (EDM) process parameters [current, pulse-on time (Ton), pulse-off time (Toff) and electrode material] on material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) during machining of aluminum boron carbide (Al–B4C) composite. This article also summarizes a brief literature review related to aluminum metal matrix composites (Al-MMCs) based on different process and response parameters, work and tool material along with their sizes, dielectric fluid and different optimization techniques used. The MMC used in the present work is stir casted using 5% (wt) B4C particles of 50 micron size in Al 6061 metal matrix. Taguchi technique is used for the design of experiments (L9-orthogonal array), while the experimental results are analyzed using analysis of variance (ANOVA). Response table for average value of MRR, EWR and SR shows that current is the most significant factor for MRR and SR, while electrode material is most important for EWR. ANOVA also confirms similar results. It is also observed that the optimum level of process parameters for maximum MRR is A3B1C3D3, for minimum EWR is A1B2C3D1, and for SR is A1B3C3D3.
Wire Electrical Discharge Machining Integrity Studies on the Aluminium Nanocomposite
2019
Nanoparticles such as SiC and B4C are popularly used as reinforcement in the AMMCs. Nanoparticles are majorly hindering the implementation of conventional machining. In addition, the profile and contour machining on the harder material is difficult in conventional machining process. Hence, non-conventional machining processes were used to shape the composite. Wire electrical discharge machining is normally proposed to cut the intricate shape with good surface finish on aluminium metal matrix composite. This present study investigates the effect of process parameters on the response parameter of WEDM on the aluminium metal matrix composite. Experiments were done by using a Taguchi’s L18 orthogonal array. The interaction of machining parameter (Ton, Toff, servo voltage, current) on the response parameter (kerf, MRR, surface roughness) was determined using analysis of variance (ANOVA). Analysing signal to noise ratio, the optimum machining parameter was determined. Regression analysis ...
Journal of Composite Materials, 2015
This study researched the effects of machining parameters on surface roughness and material removal rate in the wire electrical discharge cutting of high-density Al/B4C metal matrix composites produced via the hot pressing method. Wire tension, reinforcement percentage, wire speed, pulse-on time and pulse-off time were set as the control factors. The Taguchi L-18 (2(1)x3(4)) orthogonal array was used in the experiment design and determination of the optimum control factors. Variance analysis was applied to determine the effects of the control factors on the surface roughness and material removal rate. The results showed the most effective parameters to be pulse-on time (30.22%) for surface roughness and wire speed (83.20%) for material removal rate, and the optimum levels of the control factors to be A(2)B(1)C(2)D(1)E(1) and A(2)B(2)C(3)D(2)E(2), respectively. Predictive equations were then developed by applying linear regression analysis, and the adjusted correlation coefficients were calculated as 0.61 for surface roughness and 0.785 for material removal rate.
International Journal of Automotive Composites, 2017
Electrical discharge machining (EDM) process is one of the most commonly used non-traditional machining processes for difficult to cut materials like composites and in die making industries. The work piece material was AA 6061/10% Al 2 O 3-based metal matrix composite which was fabricated with newly developed stir casting setup. After fabrication scanning electron microscopy, mechanical testing was carried out to test properties of composite material. In EDM process, the selected EDM input parameters were pulsed current (I), pulse on time (T ON). One parameter at a time was studied to observe the responses with the variation in the selected input parameters. The metal removal rate (MRR) and gap size were observed as output responses in this experimental work. Experimental investigations showed that for higher MRR, there was high pulse current, high pulse on time. Similar effects were also observed for the gap size.
Transstellar Journal , 2019
Advancement of technology and numerous research work leads to the adoption of Composite material in the various sectors, like Aerospace, Automobile and Medical fields. In this research, Stir casting technique was utilized for fabricating the Hybrid Metal Matrix Composite (HMMC). Aluminium (Al6061) is used as a matrix material and the reinforcement used are Silicon Carbide (SiC) and Boron Carbide (B4C) with different weight percentages (Sic-5, 10 and 15 percentage & B4C-5 percentage). These fabricated composites are machined by using the Wire Cut Electrical Discharge Machine (WEDM), through which, Material Removal Rate (MRR) and Surface Roughness (Ra) has been calculated for all samples. Taguchi technique has been adopted to analyze influence of process parameters (Feed Rate, Current, Pulse on Time and Pulse off Time) and the different volumetric fraction of the reinforcement on MRR and Ra. From the developed model, it is clear that the increasing of reinforcement in the composite material had a positive impact over the MRR and Ra up to a certain extent, and later it degraded. Taguchi Optimization technique is adopted to predict the behaviors of the process parameters, and the Regression Equation was calculated for each sample to determine the MRR and Ra.
Materials Today: Proceedings, 2018
As we know non conventional machining methods are used for machining very hard materials and for making difficult shapes.Electrical discharge machining (EDM) process is one of the most commonly used non conventional machining processes for machining hard, brittle materials like composites. It is commonly used in die making industries for developing complex profiles in dies related to sheet metal work, etc. It is commonly used for machining metal matrix composites which are very hard materials. Aluminium based metal matrix composites are widely used in aeronautical and defence parts because of their advanced properties like high strength to weight ratio, etc. At first the material was fabricated using stir casting set up which was the part of research work. The work piece material selected in this study was AA 6061/ 10 %Al2O3 based metal matrix composite which was fabricated by stir casting process with the help of newly developed stir casting set up. After fabrication, the characterisation of samples was done using SEM and mechanical. The EDM process was selected for machining composite samples with input parameters like gap current (A), pulse on time (μs) and duty factor. In this machining process the output response was material removal rate. The optimisation of process parameters was done using Taguchi method with the help of ANOVA test and S/ N ratio. Analysis of variance was performed to find the significance of machining parameters in this experimental work.
International journal of automotive composites, 2017
Electrical discharge machining (EDM) process is one of the most commonly used non-traditional machining processes for difficult to cut materials like composites and in die making industries. The work piece material was AA 6061/10% Al 2 O 3-based metal matrix composite which was fabricated with newly developed stir casting setup. After fabrication scanning electron microscopy, mechanical testing was carried out to test properties of composite material. In EDM process, the selected EDM input parameters were pulsed current (I), pulse on time (T ON). One parameter at a time was studied to observe the responses with the variation in the selected input parameters. The metal removal rate (MRR) and gap size were observed as output responses in this experimental work. Experimental investigations showed that for higher MRR, there was high pulse current, high pulse on time. Similar effects were also observed for the gap size.