Investigations on Wire Electric Discharge Machining and Mechanical Behavior of Al 7075/Nano-SiC Composites

Suresh, S.; Sudhakara, D.

doi:10.1007/s40033-019-00198-x

Cited by 13 publications

(6 citation statements)

References 24 publications

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“…Therefore, the amount of discharge energy transferred to the workpiece is compromised and its substantial part got consumed by the dielectric fluid. Since voltage holds a primary Subsequently, erosion of the workpiece material takes place quickly due to instant sparking that finally yields coarse surface [23]. The same has also been indicated in the optical micrographs shown in Fig.…”

Section: Surface Roughnesssupporting

confidence: 69%

“…They reported that current intensity significantly affecting the S R and K W , while T on has vital impact on cutting rate. Suresh and Sudhakara [23] examine the WEDM parametric effects on AA7075/nano-SiC composite. They observed that voltage was the key parameter that influences the cutting rate, whereas pulse duration was prominently affecting the surface roughness.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Ishfaq

Anwar

Ali

et al. 2020

Int J Adv Manuf Technol

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The emerging demands of industry for developing the novel materials with superior mechanical properties have successfully resulted in the development of distinct materials such as Al-matrix composites. Among these composites, newly developed Al6061-7.5% SiC holds promising mechanical characteristics. But, the SiC reinforcement in the Al-matrix makes the machining of this composite challenging, thus posing a serious concern regarding its effective utilization. In this research, high-speed wire electric discharge machining (WEDM) was employed for the precise machining of a squeeze casted Al6061-7.5% SiC composite. The cutting performance of the WEDM was assessed in terms of roughness (SR), cutting rate (Cs) and kerf width (KW). Experimentation was performed according to the response surface methodology. The experimental findings were thoroughly investigated using statistical, optical and scanning electron microscopic (SEM) analyses. It has been revealed that the voltage is most influential/contributing parameter (having a percentage contribution of 25%) for controlling the SR during WEDM of Al6061-7.5% SiC composite, whereas for the CS and KW, pulse and current are the major contributing control variables with percentage contributions of 90% and 84%, respectively. At low magnitude of both current and voltages, the surface quality is improved up to 33.3%. The SEM and optical microscopic evidences reveal shallow craters, small size melt re-deposits and micro globules on the machined surface at lower settings of both the said variables. Contrarily, for achieving higher cutting speed, high values of current and voltage along with low pulse are deemed essential. In case of KW, low magnitude of current and voltage along with smaller pulse yields 20% reduction in the kerf width. The analyses revealed the conflicting nature of the studied output responses (SR, Cs and KW). Therefore, multi-objective genetic algorithm (MOGA) was used to find a parametric combination. The best combination of WEDM input parameters found is current = 3 A, voltage = 84.999 V and pulse = 10 mu. This combination gives a minimum SR of 5.775 μm with a KW of 0.3111 mm at a CS of 5.885 mm/min. The suitability of the MOGA-proposed parametric combination was witnessed through confirmation trials. Furthermore, the parametric effects have also been mathematically quantified with respect to the defined machinability parameters.

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Section: Surface Roughnesssupporting

confidence: 69%

Section: Introductionmentioning

confidence: 99%

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Ishfaq

Anwar

Ali

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…This process involves melting of the matrix material, and pouring the reinforcements into the melt and achieving an appropriate distribution and bonding through stirring. This technique is very basic and versatile, and also, being used for big quantity manufacturing [66]. The schematic representation of stir casting is shown in Figure 7.…”

Section: Friction Stir Processing/welding (Fsp/fsw)mentioning

confidence: 99%

“…Suresh and Sudhakara [66] carried out the electric discharge machining and mechanical characteristics of AA7075/n-SiC composites that are fabricated by stir casting techniques. These have incorporated n-SiC with 2, 4 and 6 %wt.…”

Section: Research On the Composites Based On Carbidesmentioning

confidence: 99%

Reinforcements, production techniques and property analysis of AA7075 matrix composites − a critical review

et al. 2021

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Aluminium alloy based metal matrix composites are being extensively used in the aerospace, automobile, defense, marine and electronic industries owing to their excellent strength, high resistance to wear, corrosion and better thermal stability. Many investigators have explored different aluminium alloy series composites, like heat treatable AA2024, AA6061 and AA7075 since the properties of these matrix alloys can be easily tailor made to suite specific application due to easy processability and heat treatability. AA7075 alloy matrix is predominantly being used, as it exhibits high ultimate tensile strength, resistance to corrosion and fatigue in the group. In the current review work, attention is focused to present types of reinforcing materials used, benefits of reinforcement hybridization, methods employed for composite production and critical property analysis, with conclusions of experimentation and the suggested prospective applications of AA7075 composites. Due to good castability and moldability variety of processing techniques in solid, semisolid and liquid states are possible. As matrix alloy, low processing temperature, ability to accommodate reinforcements and adoptability to different reinforcing techniques, it is easy to obtain optimal properties as per the application. AA7075 with small addition of copper is paved the path in the field of electronic and military applications due to high thermal and electrical conductance. Even pure metal addition & magnesium with copper facilitate good weldability, plasticity and corrosion resistance. Due to the flexibility in accommodating carbide and oxide compound reinforcements in the matrix, this matrix composite widens versatility limit due to excellent hardness and wear resistance. CNT and graphite reinforcements to this aluminium series matrix are marked as ultra-high precision components in defense field.

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“…In machining aluminium metal matrix composite (AMMC) containing 10 percentage y ash and SiC, speed of cutting was identi ed as signi cant parameter [8]. e weight percentage of reinforcement in uences R a along with gap voltage for MRR [9]. Stir-casted AA7075 with 10 percentage of SiC particles showed lower R a when turned using carbide and polycrystalline diamond (PCD) inserts [10].…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization of Wire Electrical Discharge Machining in AA7075 Metal Matrix Composite

Raju¹,

Balakrishnan²,

Priya

et al. 2022

Advances in Materials Science and Engineering

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Aluminium 7075 metal matrix composite reinforced with silicon nitride was fabricated using the stir casting technique. Composite fabricated was machined and subjected to wire electrical discharge machining to study the significant process parameter. Taguchi design of experiment using L9 orthogonal array was selected with three factors, current, pulse ON time, and wire feed at three levels. Influencing process parameters were identified using analysis of variance. Pulse ON time of 130 μs, current of 20 A, and wire feed of 1 mm/min were identified as optimized parameters for higher material removal rate. For a good surface finish, the optimized parameter was identified as 130 μs pulse ON time, 20 A current, and wire feed rate of 2 mm/min. Pulse ON time was identified as an influencing parameter followed by the current in achieving better material removal rate with good surface finish, whereas wire feed has no influence on the output parameters. Results of experimentation showed improved machining characteristics for higher pulse ON time and current for machining the synthesized composite through the Taguchi design of the experiment.

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Investigations on Wire Electric Discharge Machining and Mechanical Behavior of Al 7075/Nano-SiC Composites

Cited by 13 publications

References 24 publications

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite

Reinforcements, production techniques and property analysis of AA7075 matrix composites − a critical review

Parametric Optimization of Wire Electrical Discharge Machining in AA7075 Metal Matrix Composite

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