FEA of Electrical Discharge Machining on the Particle Metal Matrix Composite

2019 ◽  
pp. 255-266
Author(s):  
K. Benarji ◽  
Y. Ravi Kumar ◽  
S. Kanmani Subbu
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining

scholarly journals Analysis, predictive modelling and multi-response optimization in electrical discharge machining of Al-22%SiC metal matrix composite for minimization of surface roughness and hole overcut

2020 ◽  
Vol 7 ◽  
pp. 20 ◽  
Author(s):  
Subhashree Naik ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Discharge Current ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Response Optimization ◽  
Pulse On Time

Due to the widespread engineering applications of metal matrix composites especially in automotive, aerospace, military, and electricity industries; the achievement of desired shape and contour of the machined end product with intricate geometry and dimensions that are very challenging task. This experimental investigation deals with electrical discharge machining of newly engineered metal matrix composite of aluminum reinforced with 22 wt.% of silicon carbide particles (Al-22%SiC MMC) using a brass electrode to analyze the machined part quality concerning surface roughness and overcut. Forty-six sets of experimental trials are conducted by considering five machining parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken's design of experiments (BBDOEs). This article demonstrates the methodology for predictive modeling and multi-response optimization of machining accuracy and surface quality to enhance the hole quality in Al-SiC based MMC, employing response surface methodology (RSM) and desirability function approach (DFA). Finally, a novel approach has been proposed for economic analysis which estimated the total machining cost per part of rupees 211.08 during EDM of Al-SiC MMC under optimum machining conditions. Thereafter, under the influence of discharge current several observations are performed on machined surface morphology and hole characteristics by scanning electron microscope to establish the process. The result shows that discharge current has the significant contribution (38.16% for Ra, 37.12% in case of OC) in degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The machining data generated for the Al-SiC MMC will be useful for the industry.

Hybrid EDM and Grinding Hard Materials Using a Metal Matrix Composite Electrode

Volume 3 ◽  
2004 ◽  
Author(s):  
Kuen Ming Shu ◽  
Hung Rung Shih ◽  
Wen Feng Lin ◽  
G. C. Tu
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Composite Electrode ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Mold Material ◽  
Tungsten Carbides

Electrical discharge machining (EDM) has been shown to be a versatile method for machining difficult-to-work materials including heated-treated steels, tungsten carbides and various conductive ceramics. However, low machining efficiency is one of the main EDM disadvantages. The topic of how to reduce machining time and maintains reasonable accuracy has always been of research interest. The main object of the present work was to develop an electrical discharge machining and grinding (EDMG) methodology to remove the re-solidified layer through the grinding induced by a metal matrix composite electrode prior to the re-solidified layer solidification. A metal matrix composite (Cu/SiCp) electrode, with an electroless pretreatment of Cu coating on SiCp to enhance bonding status between Cu and SiCp, with a rotating device was made and employed to study the EDMG technology. Machinabilities of mold material, HPM50 mold steel and P20 WC/Co, were investigated by the combined technologies of EDMG. The machined surfaces of these materials were examined by scanning electron microscopy (SEM) and their surface roughness measured by a profile meter. From the experimental results, it was found that higher material removal rate and lower surface roughness can be achieved when suitable electrode rotating speed, SiCp size and working current are chosen. In addition, the surface roughness of both materials could be improved as compared with that following the EDM process.

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