Machining characteristics and optimisation of process parameters in micro-EDM of SiC&lt;SUB align=right&gt;p Al composites

Dev, Anand; Patel, Kaushik M.; Pandey, Pulak M.; Aravindan, S.

doi:10.1504/ijmr.2009.028541

Cited by 22 publications

(6 citation statements)

References 24 publications

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“…Thus, the increase in voltage and threshold increases the amount of thermal energy transfer to work material. At the same time the discharge gap becomes larger resulting in efficient removal of unwanted particles due to which the electrical parameters have a significant effect on response indicators [8]. In order to find optimum process parameters, TOPSIS calculations performed and it is shown in table 4.…”

Section: Analysis Of Variancementioning

confidence: 99%

“…They found the optimal condition for response indicators such as kerf width and MRR using desirability approach. Dev et al [8] assessed the machining behavior of SiCp-Al composites under different current settings. They also analyzed the effect of particulate size on machining performance and found the optimum parameteric condition for good surface texture.…”

Section: Introductionmentioning

confidence: 99%

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Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

Narasimmalu¹,

Ramabalan²

2022

Surf. Topogr.: Metrol. Prop.

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Al6063 composites are widely used in automobile, aerospace and biomedical industries due to their excellent mechanical properties. Machining of micro channels in composites is difficult for conventional machining process due to presence of hard reinforcement. Materials with base metal. Micro Electrical discharge (µED) milling is popular micromachining technique for machining simple, intricate shapes and microchannels on any conductive material. However, it a slow machining process, the identification of optimum condition has become wide research area in µEDM. The present work aims to study the influence of process variables namely voltage, spindle speed and threshold on machining characteristics of µED milling of Hybrid Metal Matrix Composites (HMMCs). Experimental trials are carried out with copper electrode at different parametric condition. Al6063-5%B4C-5%ZrSiO4 composite was fabricated using stir casting method and experimental runs were designed using general full factorial method. The significant parameters are identified using Analysis of Variance (ANOVA) and the ideal machining conditions for multi-response are determined using Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) method. The morphology of machined surface with best and worst conditions is examined using SEM. Results indicated that the voltage and threshold are the influencing parameters for considered response indicators. Recast layer thickness seems to be low with best machining conditions as compared to worst conditions. Increase in voltage and threshold increases the Material Removal Rate (MRR) and decreases the Electrode Wear Rate (EWR). Surface finish is better when the lower order of capacitance and voltage is used. MRR is increased by 48% with best machining conditions compared to worst machining condition.

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Section: Analysis Of Variancementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

Narasimmalu¹,

Ramabalan²

2022

Surf. Topogr.: Metrol. Prop.

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“…Karthikeyan et al [216] revealed that an increase in the volume fraction of SiC decreased the MRR and increased the TWR as well as SR when performing EDM of 6%-20% (volume fraction) SiC/Al composites. Dev et al [217] reported that an increase in weight percentage of SiC, as well as particle size, had resulted in a decrease in MRR and an increase in TWR and SR. Besides the SiC particles, electrical parameters are the key factors that affect MRR, TWR, and SR. Singh et al [218] machined an A6061/10% SiC composite and found that with an increase in pulse on time, the MRR, TWR, and SR increase, and the SR increases with an increase in gap voltage.…”

Section: Mill Grinding Cylindrical Grinding and Ductileregime Grindingmentioning

confidence: 99%

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Chen

2020

Adv. Manuf.

113

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Among the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiC p /Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiC p /Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiC p /Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiC p /Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiC p /Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications.

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“…At present, there are a number of different nonconventional micromachining techniques being extensively used in many industrial applications, such as laser, electrical discharge machining (EDM), electrochemical machining (ECM), abrasive jet machining, and microgrinding. These processes are used to perform precision machining of composite materials where the material removal process is not affected by hardness, strength, or toughness of the specimen materials [148,149].…”

Section: Nontraditional Machining Of Composite Materialsmentioning

confidence: 99%

“…Paul et al [153] investigated microdrilling of newly developed SiC-20% boron nitride composite. Similarly several authors examined EDM micromachining of composite materials, such as SiCp-Al [149], SiC-titanium carbide nitride (Ti 2 CN) [154,155], and SiC/Al [147]. Consequently, ECM was reported to be one of the most suitable processes for difficult-to-machine materials without a heat-affected zone.…”

Section: Nontraditional Machining Of Composite Materialsmentioning

confidence: 99%

Micromanufacturing of composite materials: a review

Hasan

Zhao

Jiang

2019

Int. J. Extrem. Manuf.

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Composite materials exhibit advantages from the combination of multiple properties, which cannot be achieved by a monolithic material. At present, the use of composite materials in miniaturized scale is receiving much attention in the fields of medicine, electronics, aerospace, and microtooling. A common method for producing miniaturized composite parts is micromanufacturing. There has been, however, no comprehensive literature published that reviews, compares, and discusses the ongoing micromanufacturing methods for producing miniaturized composite components. This study identifies the major micromanufacturing methods used with composite materials, categorizes their subclasses, and highlights the latest developments, new trends, and effects of key factors on the productivity, quality, and cost of manufacturing composite materials. A comparative study is presented that shows the potential and versatility associated with producing composite materials along with possible future applications. This review will be helpful in promoting micromanufacturing technology for fabricating miniaturized products made of composite materials to meet the growing industrial demand.

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Machining characteristics and optimisation of process parameters in micro-EDM of SiC<SUB align=right>p Al composites

Cited by 22 publications

References 24 publications

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Micromanufacturing of composite materials: a review

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Machining characteristics and optimisation of process parameters in micro-EDM of SiC<SUB align=right>p Al composites

Cited by 22 publications

References 24 publications

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO4 composite using TOPSIS method

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO4 composite using TOPSIS method

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Micromanufacturing of composite materials: a review

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Product

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Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO₄ composite using TOPSIS method