Fabrication and optimization of hybrid AA-6082-T6 alloy/8%Al2O3(Alumina)/2%Grp metal matrix composites using novel Box-Behnken methodology processed by wire-sinking electric discharge machining

Electric discharge machining has been established as an effective alternative process to conventional material removal processes for machining reinforced metal matrix composites. Wire cut electric discharge machining holes were produced in a metal matrix composite (10 vol% of SiC in Al6061), which were then investigated to determine the machinability of the material using this process. It was observed that the input factors such as the size of reinforced particles, wire tension and pulse-on time significantly affect diameter error, circularity and surface roughness. Pulse-on time, the interaction between pulse-on time and wire tension contribute to the maximum diameter error. The wire tension is the most significant factor to circularity, which is followed by the interaction between pulse-on time. In particular, wire tension with low and high tensions results in poor circularity. It has been found that there are more surface defects encountered when particle sizes are smaller, and circularity is improved when particles are in a medium size. In addition, the surface defect is reduced as the particles increase the melting resistance of the surface. The higher pulse-on time leads to higher heat and more time to degrade the surface. Therefore, low pulse-on time and wire tension gave better surface finish.

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Parametric Optimization of Electric Discharge Machining of Metal Matrix Composites Using Analytic Hierarchy Process

Micromachines ◽

10.3390/mi12111289 ◽

2021 ◽

Vol 12 (11) ◽

pp. 1289

Author(s):

Sarabjeet Singh Sidhu ◽

Timur Rizovich Ablyaz ◽

Preetkanwal Singh Bains ◽

Karim Ravilevich Muratov ◽

Evgeny Sergeevich Shlykov ◽

...

Keyword(s):

Residual Stresses ◽

Analytic Hierarchy Process ◽

Metal Matrix Composites ◽

Process Parameters ◽

Electric Discharge ◽

Metal Matrix ◽

Matrix Composites ◽

Electric Discharge Machining ◽

Analytic Hierarchy ◽

Hierarchy Process

The present study reports on the method used to obtain the reliable outcomes for different responses in electric discharge machining (EDM) of metal matrix composites (MMCs). The analytic hierarchy process (AHP), a multiple criteria decision-making technique, was used to achieve the target outcomes. The process parameters were varied to evaluate their effect on the material erosion rate (MER), surface roughness (SR), and residual stresses (σ) following Taguchi’s experimental design. The process parameters, such as the electrode material (Cu, Gr, Cu-Gr), current, pulse duration, and dielectric medium, were selected for the analysis. The residual stresses induced due to the spark pulse temperature gradient between the electrode were of primary concern during machining. The optimum process parameters that affected the responses were selected using AHP to figure out the most suitable conditions for the machining of MMCs.

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