Fabrication and experimental study to optimize the recast layer and the material removal in electric discharge machining (EDM) of AA6061-B4C composite

Gudipudi, Suresh; Selvaraj, N.; Subbu, S. Kanmani; Chilakalapalli, Surya Prakasa Rao

doi:10.1016/j.matpr.2019.07.634

Cited by 12 publications

(9 citation statements)

References 16 publications

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“…The micro-EDM of MWCNT-Al 2 O 3 composites has been reported for the higher MRR at 5vol.% MWCNT compared 2.5vol.%. 45 Gudipudi et al 34 reported that a higher current and lower pulse-on time are reason for higher MRR, whereas a lower current and moderate pulse-on time are for low average recast layer thickness (ARLT) during the EDM of a cast AA6061-4%B 4 C composite. Ranjith et al 35 reported that the AA6061-20Gr (graphite) composite tool electrode material has a better surface finish and MRR during the EDM of AZ91-5%B 4 C composites.…”

Section: Electro-discharge Machining Of Compositesmentioning

confidence: 99%

“…The various MMCs were studied for machinability via several EDM invariants such as wire EDM, 22–2324252627282930 sinker EDM, 3132333435363738 ED grinding, 39 rotary EDM, 8 ultrasonic EDM, 40 powder-mixed EDM, 41, 42 magnetic field–assisted EDM, 25 hybrid EDM, 43 magnetorheological fluid–assisted EDM, 44 micro-EDM, 45 etc. It was observed that the crater size is proportional to the discharge energy with relatively less surface damage of Al-SiC composite in EDM as compared to laser machining and abrasive water-jet machining.…”

Section: Introductionmentioning

confidence: 99%

“…Various design of experiment (DOE) techniques help in better understanding the relationships among the different input and output characteristics of an EDM process with the minimum number of trials. 25, 32, 34, 44, 50 The full factorial experimental design, as compared to fractional factorial experimental design, generally widens the doors for better understanding/analyzing/modeling of any manufacturing process. Therefore, the full factorial experimental design was used to study the effect of EDM input parameters on various geometrical features of the machined channels.…”

Section: Introductionmentioning

confidence: 99%

“…Figure 3. The SEM image of the rectangular channel (for trial: 26) with a magnified view of the recast layer.Source: Gudipudi et al34 …”

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confidence: 99%

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A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

Gudipudi¹,

Selvaraj

Subbu

et al. 2021

Journal of Micromanufacturing

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In electro-discharge machining (EDM), the material removal takes place by precisely controlled sparks that occur between tool and workpiece separated with a spark gap in the presence of a dielectric. Generally, the non-contacting type and less material removal rates are attributed to attain a good surface finish and close dimensional tolerances during an EDM of monolithic metals and alloys. But the dimensional accuracy and surface integrity parameters would considerably affect during EDM of composites due to the existence of more than one material phase constituents. Therefore, the present work aims to study and optimize the performance characteristics under various EDM conditions employed in making rectangular channels on AA6061-B4C composite material. Initially, AA6061-4wt.%B4C composites were fabricated by ultrasonically assisted stir-casting, and the improved properties were obtained from various mechanical characterizations. The EDM experiments were conducted according to the full factorial experimental design. The three levels of input conditions such as discharge Current (I), discharge duration (T On), and discharge idle time (T Off) were considered. The considered output responses are material removal rate (MRR),taper (θ) of the machined channel, tool wear rate (TWR), average surface roughness (R) of the machined surface, and average recast layer thickness (ARLT) of the machined zone. These responses are co-related with multi-objective types in the sense that the MRR has to be maximized with all other responses minimized. Hence, principal component analysis (PCA) coupled with grey relation analysis (GRA) was used for optimization in which the results were normalized, and all the responses were converted into a single response named weighted grey relation grade (WGRG) for each trial. The experimental trial, which had the highest WGRG, was considered as a local optimum. The global optimum parameters were obtained by performing the Taguchi method (TM) (higher-the-better) for the maximization of WGRG. The analysis of variance (ANOVA) was performed to know the contribution of each EDM parameter toward the WGRG. The optimum levels of Current, T On, and T Off were identified as 8 A, 25 µs, and 36 µs, respectively. Results showed that all three input parameters significantly affected the WGRG, and a higher contribution of Current (52.11%) followed by the T On (26.72%) was observed. The interaction between the Current and T Off was found to be greater than other interactions. Taper values were observed to be reduced at the combination of 8 A discharge Current and 25 µs T On. None of the input parameters significantly affected the Ra, except for Current, which showed a slight effect. ARLT values showed an increasing trend of T On from 25 µs to 45 µs but decreased slightly at 65 µs for all Current levels. The moderate Current level 6 A was observed to be favorable in reducing ARLT when compared to low (4 A) and high (8 A) for all Ton values.

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Section: Electro-discharge Machining Of Compositesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…Figure 3. The SEM image of the rectangular channel (for trial: 26) with a magnified view of the recast layer.Source: Gudipudi et al34 …”

mentioning

confidence: 99%

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A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

Gudipudi¹,

Selvaraj

Subbu

et al. 2021

Journal of Micromanufacturing

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“…Salimi et al 7 used a friction stir-based process to fabricate the cooling channel profiles on aluminum AA6061T6. Gudipudi et al 8,9 employed sinker-electric discharge machining (EDM) to make rectangular channels on AA6061-B 4 C composites. However, these composites in which a certain amount of reinforcement (RF) particles are incorporated into the base metal matrix showed improved performance in thermal management systems.…”

Section: Introductionmentioning

confidence: 99%

A study on geometrical features of electric discharge machined channels on AA6061-4%B₄C composites

Gudipudi

Selvaraj

Chandra

et al. 2020

Measurement and Control

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The aluminum alloy AA6061-4wt.% boron carbide (B4C) particulate metal matrix composites were fabricated by the stir casting method. The die-sinker electric discharge machining was performed to make the rectangular mini channels on these composites. The full factorial experimental design that consists of three input conditions, the current ( I), discharge duration ( T-on), and discharge idle time ( T-off) at three levels each (33 = 27 total runs), was used for experimentation. The volume, V, the taper, θ (along with the depth), the lateral overcut (along the width), and the difference in depth, Δ d (between total depth and depth up to the tapered profile) at entrance and exit cross-sectional profiles of the channel were considered as output responses. The θ, lateral overcut, and Δ d were calculated from the entrance and exit profiles which were obtained by extracting the data points of each channel with the help of an optical profile projector. The computer-aided geometric model was developed to estimate the volume. A set of optimum electric discharge machining parameter levels were identified for maximum V and a minimum of θ, lateral overcut, and Δ d. Analysis of variance was performed to identify the significant parameter and the contribution toward output responses. Results showed that the volume was found to be maximum at higher I (8 A) and lower T-On (25 µs) conditions. The taper was found to decrease with the increase in current but both lateral overcut and Δ d increased. Both I and T-On are found to be the significant parameters affecting both V and Δ d, whereas current is for θ and lateral overcut. In some cases, it was observed that there is a considerable difference in the θ and the lateral overcut values in the entrance and exit portions for the same channel. It is because of the randomly dispersed B4C particles which alter the material removal mechanism.

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Effect of Process Parameters on Volume and Geometrical Features of Electric Discharge Machined Channels on a Cast AA6061-B4C Composite

Gudipudi

Selvaraj

Dongari

et al. 2020

Lecture Notes in Mechanical Engineering

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Fabrication and experimental study to optimize the recast layer and the material removal in electric discharge machining (EDM) of AA6061-B4C composite

Cited by 12 publications

References 16 publications

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

A study on geometrical features of electric discharge machined channels on AA6061-4%B₄C composites

Effect of Process Parameters on Volume and Geometrical Features of Electric Discharge Machined Channels on a Cast AA6061-B4C Composite

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Fabrication and experimental study to optimize the recast layer and the material removal in electric discharge machining (EDM) of AA6061-B4C composite

Cited by 12 publications

References 16 publications

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

A study on geometrical features of electric discharge machined channels on AA6061-4%B4C composites

Effect of Process Parameters on Volume and Geometrical Features of Electric Discharge Machined Channels on a Cast AA6061-B4C Composite

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A study on geometrical features of electric discharge machined channels on AA6061-4%B₄C composites