Wear Behavior of B4C reinforced Al6063 matrix composites electrode fabricated by stir casting method

2020 ◽  
Author(s):  
MATHALAI SUNDARAM C ◽  
Radha Krishnan B ◽  
HARIKISHORE S ◽  
V. Vijayan
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Wear Behavior ◽  
Casting Process ◽  
Surface Characteristics ◽  
Stir Casting ◽  
Composite Electrodes ◽  
Die Steel ◽  
Hardness Tester ◽  
Good Surface

The aim of the study is to predict the surface topological characteristics of Al-B4C composite electrodes and the OHNS Die steel in the Electrical Discharge Machining (EDM) Process. The surface characteristics of Composite electrodes are evaluated by using Scanning Electron Microscopy (SEM) and EDAX Analytical Method. Surface roughness and hardness of the OHNS die steel was measured by the Stylus probe and Brinnel hardness. The composite electrodes prepared by the Aluminium 6063 and B4C materials. Both elements are mixed at molten state in the stir casting process at different compositions. The chemical composition properties of the Composite electrode is analyzed by the SEM and EDAX testing. The surface Roughness of the OHNS steel measured by the Brinell hardness tester. Based on the SEM and EDAX results, the 92% Al 8% B4C was producing the good surface roughness in OHNS die steel.

Multi-Response Optimization of Electrochemical Machining of Al-Si/B4C Composites Using RSM

2013 ◽  
Vol 3 (3) ◽  
pp. 42-56 ◽  
Author(s):  
Sadineni Rama Rao ◽  
G. Padmanabhan
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Casting Process ◽  
Stir Casting ◽  
Machining Parameters ◽  
Electron Microscopic ◽  
Sem Images

The present work reports the electrochemical machining (ECM) of the aluminium-silicon alloy/boron carbide (Al-Si /B4C) composites, fabricated by stir casting process with different weight % of B4C particles. The influence of four machining parameters including applied voltage, electrode feed rate, electrolyte concentration and percentage of reinforcement on the responses surface roughness (SR) and radial over cut (ROC) were investigated. The process parameters are optimized based on the response surface methodology (RSM) and the optimum values for minimizing surface roughness and radial over cut are voltage 15.25 V, feed rate 1.0 mm/min, electrolyte concentration 13.56g/lit and percentage of reinforcement 7.36 wt%. The quality of the machined surfaces is studied by using scanning electron microscopic (SEM) images. The surface plots are generated to study the effect of process parameters and their interaction on the surface roughness and radial over cut, for the machined Al-Si/B4C composites.

scholarly journals Evaluation of Copper-Based Alloy (C93200) Composites Reinforced with Marble Dust Developed by Stir Casting under Vacuum Environment

Materials ◽  
2019 ◽  
Vol 12 (10) ◽  
pp. 1574 ◽  
Author(s):  
Santosh Kumar Rajak ◽  
Amit Aherwar ◽  
Deepak Rajendra Unune ◽  
Mozammel Mia ◽  
Catalin I. Pruncu
Keyword(s):  
Selection Index ◽  
Surface Characteristics ◽  
Stir Casting ◽  
Dust Particles ◽  
Wear Properties ◽  
Weight Percentage ◽  
Suitable Material ◽  
Hardness Tester ◽  
Marble Dust ◽  
Copper Based Alloy

Copper-based alloy (C93200) composites reinforced with a different weight percentage of marble dust particles (1.5, 3, 4.5, and 6 wt.%) were developed by stir casting method under vacuum environment. By using this type of reinforcement, it was possible to detect a suitable material for bearing applications. The manufactured material was characterized for its mechanical properties using a micro-hardness tester. A universal INSTRON-5967 machine was used to detect the yield and tensile strength. Further the hardness features were measured using a Walter Uhl model machine, whereby the wear characteristics were simulated under the pin-on-disc tribometer under different working conditions in ambient temperature (23 °C). Next, the preference selection index (PSI) technique that considers multi-criteria decision-making was proposed to validate which material was the best candidate. For the selection of material criteria, some specific material intrinsic properties—such as, density, void fraction, hardness resistance along with tensile, compressive, and flexural strength—were proposed and the surface characteristics linked to friction coefficients along wear properties. It was found that the novel composite material containing 4.5 wt.% of marble dust provided the best combination of properties and is a suitable candidate material for bearing applications.

scholarly journals Effect of bagasse ash reinforcement on Al356 matrix composite manufactured by two stage stir casting process

2018 ◽  
Vol 8 (04) ◽  
Author(s):  
Vaibhav Dardare ◽  
S. G. Kulkarni
Keyword(s):  
Tensile Strength ◽  
Compression Strength ◽  
Testing Machine ◽  
Casting Process ◽  
Stir Casting ◽  
Experimental Result ◽  
Compression Tests ◽  
Two Stage ◽  
Weight Percentage ◽  
Hardness Tester

In the present work Al356-Bagasse ash composites are produced by two stage stir casting method and subsequently various properties like compression strength, tensile strength, hardness of Al356 are studied. Al356 alloy is reinforced with bagasse ash particles of the various weight percentage (2,4 and 6% wt.). An experimental result shows uniform distribution of the bagasse ash particles in the matrix of the Al356 leading to increase in the mechanical strength of the composites. The tensile and compression tests are carried out with the help of Universal Testing Machine and it was observed that ultimate tensile strength, yield strength and compression strength increases with increase weight percentage of bagasse ash in the composite, while percentage elongation decreases. The hardness of the composites are measured by brinell hardness tester and it was observed that hardness of the composite material increases with increase in weight percentage of bagasse ash particles.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

Production and Assessment of AZ91 Reinforced with Nano SiC through Stir Casting Process

2022 ◽  
Vol 1048 ◽  
pp. 9-14
Author(s):  
J. Allen Jeffrey ◽  
S. Suresh Kumar ◽  
P. Hariharan ◽  
M. Kamesh ◽  
A. Mithun Raj
Keyword(s):  
Testing Machine ◽  
Thermal Characteristics ◽  
Hardness Test ◽  
Casting Process ◽  
Stir Casting ◽  
Industrial Applications ◽  
Hardness Tester ◽  
Two Samples ◽  
Peak Increase ◽  
Magnesium Composites

Magnesium, a light weight alloy used in multiple engineering industrial applications because of its good Physical, Chemical and Thermal characteristics. Magnesium composites play an important role in partial or entire replacement of numerous alloys.This current work deals with Nano silicon carbide of about 100nm was incorporated with AZ91magnesium alloy through liquid state composite processing. Two samples are made using 0% Nano SiC and 3% Nano SiC and are characterized through tensile test in Universal Testing Machine, Micro hardness test in Vickers hardness tester and Microstructure in Optical Microscopy. From the study it was clear that there is a peak increase in hardness of about 36% when compared to as casted AZ91.

A Study on the Die-Sinking Micro-Electrical Discharge Machining of EN-24 Die Steel Using Various Electrode Materials

2014 ◽  
Vol 984-985 ◽  
pp. 73-82 ◽  
Author(s):  
A. Kadirvel ◽  
P. Hariharan ◽  
M. Mudhukrishnan
Keyword(s):  
Surface Roughness ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Die Steel ◽  
Micro Holes

Micro-EDM is an extensively used machining process for the fabrication of micro-holes with various advantages resulting from its characteristics of non-contact and thermal process. In this micro-fabrication technique, processing parameters greatly affect processing efficiency and stability. An experimental investigation on die-sinking Micro-EDM of EN-24 die steel using various electrodes such as tungsten, copper, copper tungsten and silver tungsten has been carried out. The present study aims to assess the quality and accuracy of the produced micro-holes, machining stability, material removal rate (MRR), tool wear ratio (TWR), surface roughness (Ra), Heat affected zone (HAZ) and overcut (OC). In addition, the influence of gap voltage, capacitance and discharge energy on the performance of the process has also been investigated. Experimental results proved that the overall performance of the copper electrode is found to be optimum with high MRR, thin HAZ though copper shows higher TWR, surface roughness and overcut.

scholarly journals Study of the Transcription Effects of Pressing Dies with Ultrasonic Polishing on Glass Molding

Processes ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 2083
Author(s):  
Ken-Chuan Cheng ◽  
Chien-Yao Huang ◽  
Jung-Chou Hung ◽  
A-Cheng Wang ◽  
Yan-Cherng Lin
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Sine Wave ◽  
Optical Systems ◽  
Lens Array ◽  
Glass Molding ◽  
Good Surface ◽  
Good Surface Roughness ◽  
Micro Lens Array

The micro lens array (MLA) has played an important role in optical systems for the past few years, and the precision of pressing dies has dominated the quality of MLAs in glass molding. Few studies have covered the transcription effects on surface roughness of pressing dies for this technology. Therefore, this research utilized pressing dies to produce a sine-wave lens array on glass molding, to transform the Gauss-distributed spotlight into a uniform straight one and then characterize the transcription effects of these lenses. Pressing dies with a sine-wave shape were firstly cut by wire electrical discharge machining (WEDM), and then ultrasonic polishing using diamond abrasives was applied to finish the sine-wave surface with an original roughness of 0.2 μm Ra. Next, the sine-wave lens arrays were pressed by glass molding at the appropriate pressure and temperature, before evaluating the transcription effects of transforming the Gauss-distributed spotlight into a uniform straight one. The result showed that the sine-wave lens array stuck easily to the pressing die and then ruptured during glass molding due to the poor surface roughness of pressing tool. However, the diamond abrasive with appropriate sizes could establish good surface roughness on pressing dies via ultrasonic polishing, and the pressing die with a low surface roughness of 0.08 μm Ra was able to successfully perform MLA in the glass molding. However, only pressing dies with a surface roughness smaller than 0.023 μm Ra could produce precision glass lenses to transform the Gauss-distributed spotlight into a uniform straight one.

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