Wire electrical discharge machining of AA6063-TiC particle reinforced metal matrix composites using Taguchi method

Saravanan, S.; Senthilkumar, P.; Ravichandran, M.; Shivasankaran, N.

doi:10.1088/2053-1591/aadab7

Cited by 13 publications

(6 citation statements)

References 15 publications

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“…Analysis indicates that the maximum machining rate M p decreases as M ex reduces because of the deterioration in the discharge of erosion products as the electrode is introduced in the material, and the number of working pulses is reduced [182, 183, 184].…”

Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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The productivity of electrical discharge machining (EDM) is relatively low owing to the natural laws of electrical erosion. Precise EDM demands uninterrupted control of the discharge gap and adjustment of process parameters. It is particularly critical for processing large workpieces with complex linear surfaces and for materials with threshold conductivities such as the new advanced ceramic nanocomposites Al2O3+TiC and Al2O3+SiCw+TiC(30–40%). In these cases, adequate flushing of erosion products is hampered by the geometry of the working space or by the small value of the required discharge gap, which does not exceed 2.2–2.5 μm. The methods of adaptive control in modern computer numerical control systems of EDM equipment based on measuring the electrical parameters in the working zone have been shown to be ineffective in the cases described above. This study aims to investigate the natural phenomena of material sublimation under discharge pulses for conductive ceramics and nanocomposites. The measured conductivities of the samples are higher than the percolation threshold. However, the question of machinability remains open owing to detected processing interruptions and poor quality of machined surfaces. New knowledge on EDM of conductive ceramics and nanocomposites can improve the final quality of the machined surfaces and productivity of the method by the introduction of advanced monitoring and control methods based on acoustic emissions. The manuscript presents an up-to-date overview and current state of the research on the subject area. The obtained morphology of the samples and discussion of the findings complete the experimental part of the study. The scientific basis for a new type of adaptive control system is provided. This can improve the effectiveness of parameter control for machining conductive ceramics and nanocomposites and contribute to an increase in the EDM performance for the most critical cases.

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Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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“…Moreover, the SR attained in this current study was lower by using Tedra Boline TD wire as compared with the literature study. 24…”

Section: Effect Of Wedm Process Parameters On Performance Measuresmentioning

confidence: 99%

“…Mainly, the SR value has been reduced in the dielectric medium deionized water by 42.57% as compared with oil + wax + paraffin dielectric medium. Saravanan et al 24 analyzed the effect of the wt.% of TiC particles and the WEDM parameters of aluminum-based TiC composites. From this study, the authors concluded that the SR was enhanced with increasing the wt.% of TiC 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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“…Ra = −9.1 + 0.6A + 0.152Ton − 0.281 WFR − 0.023A × A − 0.0109A × Ton + 0.0129A × WFR (6) The corresponding equations are: The corresponding equations are: KRW = 0.0800 − 0.01750A + 0.000111Ton + 0.00722WFR + 0.001458A × A + 0.000083A × Ton − 0.000208A × WFR The corresponding equations are KRW =0.0422 − 0.00983A + 0.003183Ton + 0.000292A × A − 0.000000A × Ton (11) Ra = −17.7 + 2.14A + 0.025Ton − 0.0687A × A + 0.00088A × Ton (…”

Section: Resultsmentioning

confidence: 99%

“…al. [11] experimentally identified the critical parameters that will affect the material removal rate and surface roughness of AA6063-TiC composite materials for different percentage of reinforcement of TiC. The major factor affecting the output parameters were found to be the percentage of reinforcement followed by the pulse-on-time.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Kerf Width and Surface Roughness of Al6351 Based Composite in Wire-Cut Electric Discharge Machining Using Mathematical Modelling

et al. 2022

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The machining of composite materials has been an area of intense research for the past couple of decades due to its wide range of applications, from automobiles to air crafts or from boats to nuclear systems. Non-conventional machining, especially electric discharge machining (EDM), is found to be a good machining option for meeting the required outputs. To overcome the challenges of machining complex shapes, wire electric discharge machining (WEDM) was developed. Al6351 composites was observed to be extensively used in nuclear applications. Therefore, identifying the kerf width and surface roughness are important criteria for the dimensional accuracy of the final product. The present work aims at predicting the behavior of the two major machining parameters which are kerf width and surface roughness of Al6351 composites in wire EDM by creating a mathematical model using ANOVA for different combinations of the reinforcements and comparing the variations in the coefficients for different combinations of reinforcements. The developed model has been validated by conducting similar set of experiments in Al6351-5% SiC-1% B4C hybrid composite. From the work, it was identified that pulse on time and current are the major contributing factor for kerf width and wire feed rate was observed to be contributing to the surface roughness. The validation results show an average variation of 8.17% for kerf width and 11.27% for surface roughness. The work can be successfully utilized for prediction of the kerf width and surface roughness of the composites manufactured with Al6351 as the base matrix material.

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Wire electrical discharge machining of AA6063-TiC particle reinforced metal matrix composites using Taguchi method

Cited by 13 publications

References 15 publications

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

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

Prediction of Kerf Width and Surface Roughness of Al6351 Based Composite in Wire-Cut Electric Discharge Machining Using Mathematical Modelling

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