Experimental Study on Blasting Erosion Arc Machining of 50 Vol% SiC/Al Matrix Composites

2016 ◽  
Author(s):  
Jipeng Chen ◽  
Lin Gu ◽  
Wansheng Zhao
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Negative Electrode ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Machining Performance ◽  
High Fraction ◽  
Al Matrix Composites ◽  
Blasting Erosion Arc Machining ◽  
Al Matrix

Machining performance of high fraction SiC/Al matrix composites (e.g., 50 vol% SiC/Al) is very limited because of their reinforced SiC particles. In order to study the machinability of high fraction SiC/Al matrix composites with blasting erosion arc machining (BEAM), factorial experiment was employed under the negative electrode machining condition. It was found that when peak current was 500 A, MRR (material removal rate) could be as high as 6,000 mm3/min. Besides, surface integrity under different machining parameters was also investigated. Finally, a 50 vol% SiC/Al composites workpiece was successfully machined with BEAM, which demonstrated that BEAM is capable for the machining of high fraction SiC/Al matrix composites.

High efficiency blasting erosion arc machining of 50 vol.% SiC/Al matrix composites

2017 ◽  
Vol 232 (12) ◽  
pp. 2226-2235 ◽  
Author(s):  
Jipeng Chen ◽  
Lin Gu ◽  
Yingmou Zhu ◽  
Wansheng Zhao
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Pulse Interval ◽  
Machining Efficiency ◽  
Matrix Composites ◽  
Factorial Experiments ◽  
Machining Performance ◽  
Al Matrix Composites ◽  
Blasting Erosion Arc Machining ◽  
Al Matrix

Blasting erosion arc machining (BEAM) is adopted to improve the machining efficiency of high fraction (50 vol.%) SiC/Al matrix composites. Results of the fractional factorial experiments and full factorial experiments indicate that the electrical parameters (peak current, pulse duration and pulse interval) are the main impact factors of the machining efficiency, and when the peak current is 500 A, the pulse duration is 8 ms and the pulse interval is 2 ms, the material removal rate reaches to 6000 [Formula: see text]/min. Furthermore, the material removal rate was optimized and could be as high as 7500 [Formula: see text]/min with the tool wear ratio about 10%. Simulation of the single discharge heat transfer illustrates that the SiC particles have negative influence on the machining performance due to their temperature dependent characteristics. The polarity effect was also studied and it is disclosed that different machining polarities have different influences on the machining performance, surface integrity and even the formation of SiC particles. Finally, a 50 vol.% SiC/Al workpiece was machined with blasting erosion arc machining.

An Orthogonal Experimental Study of WEDM-HS of Particle-Reinforced 6061 Al Matrix Composites with 20-Vol% Al2O3

2014 ◽  
Vol 563 ◽  
pp. 21-24 ◽  
Author(s):  
Jiang Wen Liu ◽  
Yong Zhong Wu
Keyword(s):  
Pulse Duration ◽  
Material Removal Rate ◽  
Duty Cycle ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Al Matrix Composites ◽  
Al Matrix

An investigation has been made into the machining feasibility when wire electro-discharge machining with an extremely high travelling speed of wire electrode (WEDM-HS) has been employed to process particle-reinforced 6061 Al matrix composites with 20-vol% Al2O3 (20ALO). And in this study, for the water based emulsion is used as working liquid, there exists an electrochemical effect. And thus, the EDM spark can operate under a relatively large spark gap size condition, and this would be helpful for the removal of the loosen particles and the machined debris. In this study, the material removal rate (MRR) has been examined. Since there are many factors that can influence the MRR during the wire electro-discharge machining process, in order to determine which factor has the most significant effect on the MRR and to obtain the optimal machining parameters, the relative importance of the various machining parameters on material removal rate was analysed by employing an orthogonal design. The results of the orthogonal analysis show that to obtain a high MRR for WEDM-HS machining of 20ALO materials, the duty cycle has the most significant effect on the MRR among current, pulse duration and duty cycle. And the impact of significance for the different factors follows the sequence of duty cycle > current > pulse duration. And under the experiment condition of this study, a duty cycle of 1:4, a current of 5A and a pulse duration of 32μs is the best arrangement for the MRR.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

Research on the Machining Performance of SiC/Al Composites Utilizing the BEAM Process

2015 ◽  
Author(s):  
Jipeng Chen ◽  
Lin Gu ◽  
Hui Xu ◽  
Wansheng Zhao
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Machining Efficiency ◽  
Machining Performance ◽  
Peak Current ◽  
Tool Wear Ratio ◽  
Large Peak ◽  
Performance Results ◽  
The Relationship ◽  
Blasting Erosion Arc Machining

The Blasting Erosion Arc Machining (BEAM) process was applied to improve the machining efficiency of SiC/Al composites. A set of experiments were conducted on 20 vol% SiC/Al composites to find out the relationship between the parameters and machining performance. Results revealed that when the peak current was 500 A, the material removal rate (MRR) could be greater than 8,200 mm3/min and the tool wear ratio (TWR) was about 2%. Besides, the influence of polarity on the surface properties was also studied by using scanning electron microscope (SEM) and metalloscope. It disclosed that machining with a large peak current and a negative BEAM is suitable for bulk mass material removal, while the surface quality could be improved by applying the positive BEAM. Finally, a machined sample demonstrated the fesibility of BEAM for the machining of SiC/Al materials.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

scholarly journals MACHINABILITY STUDY ON AL- 10% TIC COMPOSITES AND OPTIMUM SETTING OF DRILLING PARAMETERS IN ELECTROCHEMICAL MICRO MACHINING USING GREY RELATIONAL ANALYSIS

2014 ◽  
Vol 44 (4) ◽  
pp. 331-338
Author(s):  
S. DHARMALINGAM ◽  
P. MARIMUTHU ◽  
K. RAJA
Keyword(s):  
Material Removal Rate ◽  
Grey Relational Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Matrix Composites ◽  
Micro Machining ◽  
Machining Performance ◽  
Relational Analysis ◽  
Grey Relational Grade ◽  
Grey Relational

This paper investigates the influence of the process parameters like machining voltage, electrolyte concentration, frequency on the over cut and Material Removal Rate (MRR) on drilling of Al- 10% TiC Metal Matrix composites using Electrochemical Micro Machining (EMM) through taguchi methodology and grey relational analysis. Based on the analysis, optimum levels of parameters were determined and the same to validate through the confirmation test. Experimental results are in close agreement with the developed model. The confirmation results reveal that, there is considerable improvement in Material Removal Rate, Overcut. Grey relational grade are improved by 89.5 %, 57.9% and 95.16 % respectively. It is observed that the machining performance can be effectively improved with respect to initial parametric setting.

scholarly journals Investigating the Material Removal Rate Parameters in ECM for Al 5086 Alloy-Reinforced Silicon Carbide/Flyash Hybrid Composites by Using Minitab-18

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
Bhiksha Gugulothu ◽  
P. S. Satheesh Kumar ◽  
Bathula Srinivas ◽  
Alapati Ramakrishna ◽  
S. Vijayakumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Experimental Tests ◽  
Stir Casting ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Casting Method

This study explained about machining parameters of Al5086/Flyash/Sic hybrid metal matrix composites by the Taguchi technique. Al5086 reinforced in SiC (5–10 wt %) and 8% weight of flyash are retained as constants. The specimens are prepared with the help of the stir casting method. The material removal rate was examined by electrochemical machining under various parameters such as feed rate (0.15–0.30 mm/min), voltage (10–20 V), and electrolyte concentration (20–35 g/litre). Taguchi’s L16 orthogonal array was selected for design of experiments (DOEs), and 16 experimental tests were conducted to examine the effect of the selected machining parameters employed to identify the best optimal levels and also to investigate the effect of electrochemical machining parameters on MRR determined by Minitab-18.

scholarly journals A Comprehensive Study on Processing Ti–6Al–4V ELI with High Power EDM

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 303
Author(s):  
Panagiotis Karmiris-Obratański ◽  
Emmanouil L. Papazoglou ◽  
Beata Leszczyńska-Madej ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
High Power ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Performance

Electrical Discharge Machining (EDM) consists of a non-conventional machining process, which is widely used in modern industry, and especially in machining hard-to-cut materials. By employing EDM, complex shapes and geometries can be produced, with high dimensional accuracy. Titanium alloys, due to their unique inherent properties, are extensively utilized in high end applications. Nevertheless, they suffer from poor machinability, and thus, EDM is commonly employed for their machining. The current study presents an experimental investigation regarding the process of Ti–6Al–4V ELI with high power EDM, using a graphite electrode. Control parameters were the pulse-on current (Ip) and time (Ton), while Machining performances were estimated in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The machined Surface Roughness was calculated according to the Ra and the Rt values, by following the ISO 25178-2 standards. Furthermore, the EDMed surfaces were observed under optical and SEM microscopy, while their cross sections were also studied in order the Average White Layer Thickness (AWLT) and the Heat Affected Zone (HAZ) to be measured. Finally, for the aforementioned indexes, Analysis Of Variance was performed, whilst for the MRR and TMRR, based on the Response Surface Method (RSM), semi-empirical correlations were presented. The scope of the current paper is, through a series of experiments and by employing statistical tools, to present how two main machining parameters, i.e., pulse-on current and time, affect major machining performance indexes and the surface roughness.

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