An investigation on effects of wire electrical discharge machining parameters on surface roughness of newly developed hybrid metal matrix composite

Lal, Shyam; Kumar, S. Bharani; Khan, Zahid A.; Siddiquee, Arshad Noor

doi:10.1177/0954405413506703

Cited by 12 publications

(7 citation statements)

References 17 publications

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“…The recast layer due to its physical characteristic and metallurgical structure consists of many cracks and voids and has undesired influences on the mechanical properties and surface integrity of the workpiece. 21–24 By comparison with coarse grain materials, the UFG materials have higher grain boundaries’ energy 6,25,26 due to SPD and are more prone to the microstructural changes at the surface layers during EDM process.…”

Section: Introductionmentioning

confidence: 99%

Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining

Mahdieh

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Ultra-fined grain materials are thermodynamically unstable and when they are exposed to a high external thermomechanical energy, such as electrical discharge machining process, many microstructural changes will occur in them. However, in the electrical discharge machining process, the recast layer and heat affected zone are the undesired and inevitable consequences of this process, which have several adverse effects on the surface layers of the workpiece including microstructural changes, grain growth, alternation of hardness, initiation of micro-cracks and changing the composition. All of which deteriorate the surface integrity. In this article, the effects of the electrical discharge machining process on the ultra-fined grain steel samples have been studied through investigating the microstructure of the recast layer and heat affected zone via scanning electron microscopy, optical microscopy and X-ray diffraction technique. The thickness of the recast layer and heat affected zone as well as the cracks’ density and the hardness profile of the ultra-fined grain samples was measured and the results were compared with coarse grain samples. Results show that the undesired effects of electrical discharge machining process on the ultra-fined grain samples are more considerable than the coarse grain ones; for instance, by comparison with coarse grain samples, relatively thicker recast layer and heat affected zone are formed in the ultra-fined grain samples, in which the microstructure changed more considerably. In addition, on one hand, the more extended cracks on the electrical discharge machined surface of the ultra-fined grain samples were observed, and on other hand, the hardness profile of the ultra-fined grain samples varies more noticeably from the surface to the depth.

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Section: Introductionmentioning

confidence: 99%

Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining

Mahdieh

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…MMCs are different from monolithic materials because of the reinforced ceramic particles. Therefore, it is very complicated to optimize the machining of MMCs and manufacture parts with low tolerance [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

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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“…The surface finish of MMCs after WEDM was significantly different than that of unreinforced matrix alloy. Lal et al 47 investigated the effects of WEDM parameters on the surface roughness of newly developed hybrid Al7075/Al 2 O 3 /SiC MMC. Pulse-on-time, pulse current and pulse-off-time were identified as the significant process parameters, whereas the wire drum speed had insignificant effect on the machining responses.…”

Section: Introductionmentioning

confidence: 99%

Machinability of cenosphere particulate–reinforced AA6061 aluminium alloy prepared by compocasting

Rahman

Dey

Pandey

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Cenosphere fly ash particles as waste by-product of gas thermal power plant are successfully incorporated into AA6061 aluminium alloy by improved wettability casting process called compocasting technique to enlarge the application barrier of existing advanced metal matrix composites due to their high fabrication cost. Thereafter, microstructure, interface and composition of the prepared composites were analysed from the X-ray diffraction analysis patterns and scanning electron microscopy equipped with energy-dispersive X-ray techniques. Furthermore, machinability characteristics were identified by wire electrical discharge machining to explore the co-relations among the machining variables and the performance measures such as cutting rate, kerf width and surface roughness for the prepared composites by varying one parameter at a time and keeping the other parameters as constant. The morphological study reveals that there is a uniform distribution of fly ash particles in aluminium matrix phase without formation of any intermetallic compound caused by interfacial reaction. The machinability study indicates that pulse-on-time and pulse-off-time are the most significant process variables that affect the machining performance of the prepared composites. However, wire feed is found to impose the least significant effect among the three process parameters. Also, the neat AA6061 aluminium alloy (0% AA6061/cenosphere composites) exhibited superior machining performance compared to both the reinforced composites (4% and 8%) at similar machining conditions.

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An investigation on effects of wire electrical discharge machining parameters on surface roughness of newly developed hybrid metal matrix composite

Cited by 12 publications

References 17 publications

Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining

Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

Machinability of cenosphere particulate–reinforced AA6061 aluminium alloy prepared by compocasting

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