Evaluation of recast layer and parametric optimization of EDM process on aluminium based HMMCs using grey relational analysis

Senthilkumar, T.S.; Muralikannan, R.

doi:10.1088/2053-1591/ab3d73

Cited by 16 publications

(3 citation statements)

References 27 publications

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“…5 The composite materials fabricated by incorporating TiC particles utilizing the stir casting technique have accomplished consistent scattering in the matrix alloy with an absence of porosity. 6 Specific strength and wear resistance have been improved by increasing the wt.% of TiC particles. 7 The machining of MMCs is very difficult due to the presence of hard reinforcement particles.…”

Section: Introductionmentioning

confidence: 99%

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Sivasankaran¹,

Muralikannan²,

Ramkumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

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Section: Introductionmentioning

confidence: 99%

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Sivasankaran¹,

Muralikannan²,

Ramkumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…The formation of violent sparks and the wire's deviance from its original course are caused by the high discharge energy parameters [20]. When the discharge energy input parameters are high, the surfaces of electric discharge machined parts get rippled, heated and, recast, and cracks appear over and over again [21,22]. The impacts of input machining parameters, such as servo voltage, pulse on time, pulse off time, and wire tension, on SR in WEDM, were examined by Giovanna Gautier et al [23].…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

Vijayakumar,

Chandradass

2024

Mater. Res. Express

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The current study investigates experimentally the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel. WEDM is used to manufacture gears, shafts, spindles, camshafts, and other mechanical controlling components. In order to analyse the three performance parameters such as profile error, material removal rate (MRR), and surface roughness (SR), five WEDM parameters were employed in the trials: wire feed (Wf), wire tension (Wt), servo voltage (SV), discharge arc-off time (Toff), and arc-on time (Ton). When compared to the effects of arc on time and servo voltage on MRR, wire feed rate and tension are less important. Higher arc-on time and servo voltage have produced more profile inaccuracy. Decreased wire tension values cause the surface roughness to be more significant and result in lower roughness. As the voltage increases, an uneven surface with a large globule and a deep crater forms on the machined surface. The recast layer becomes thicker at a higher arc on time and servo voltage.

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“…Two electrodes are placed on the distance that correlates to the conductivity of the material to be processed and there is dielectric permittivity of the medium between two electrodes. The material with higher conductivity requires a larger space between electrodes [21][22][23]. The material with lower conductivity is normally called the workpiece electrode, while material of high conductivity is a tool electrode-the destruction of the workpiece should occur more intensively that the destruction of the tool, otherwise the technology has no sense.…”

Section: Introductionmentioning

confidence: 99%

Electrical Discharge Machining of Oxide Nanocomposite: Nanomodification of Surface and Subsurface Layers

Grigoriev

Волосова

Okunkova

et al. 2020

JMMP

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The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 + 30% of TiC was electroerosively machined in a water and hydrocarbon oil. The process of electrical discharge machining is accompanied by oscillations that were registered by diagnostic means. The obtained surface of the samples was researched by the means of scanning electron microscopy and X-ray photoelectron spectroscopy. The observed surface and subsurface changes provide grounding for the conclusions on the nature of processes and reactions that occur between two electrodes and nanomodification of the obtained surfaces that can be an advantage for a series of applications.

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Evaluation of recast layer and parametric optimization of EDM process on aluminium based HMMCs using grey relational analysis

Cited by 16 publications

References 27 publications

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

Electrical Discharge Machining of Oxide Nanocomposite: Nanomodification of Surface and Subsurface Layers

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