Vibration-assisted electrical arc machining of 10% B4C/Al metal matrix composite

2019 ◽  
Vol 234 (6) ◽  
pp. 1156-1170
Author(s):  
Shrihar Pandey ◽  
Pankaj K Shrivastava
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrical Arc ◽  
Unconventional Machining

To shape advanced engineering materials, many unconventional machining processes have been developed. Electrical discharge machining is such an unconventional machining process which is very popular nowadays but it is limited by poor material removal efficiency. Electrical arc machining is another unconventional machining process which is quite similar to electrical discharge machining and is now gaining attention from research fraternity due to its high material removal efficiency. In the present research, an innovative unconventional machining process known as vibration-assisted electrical arc machining has been developed. The performance of vibration-assisted electrical arc machining has been evaluated during machining of Al–B4C metal matrix composite by considering peak current, flushing velocity of dielectric and tool vibrations as input control factors. The quality characteristics considered were material removal rate, tool wear rate, relative electrode wear rate and surface roughness. It has been observed that vibration-assisted electrical arc machining results in approximately 3000% more material removal rate as compared to conventional electrical discharge machining during machining of Al–B4C metal matrix composite. The effects of various input control factors on output parameters have also been discussed. Further modelling and optimization of the process parameters has also been done by artificial intelligence approach.

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.

Application of the Entropy Weight and TOPSIS Method on Al–12% SiC Metal Matrix Composite during EDM

2014 ◽  
Vol 4 (4) ◽  
pp. 49-63 ◽  
Author(s):  
Bharat Chandra Routara ◽  
Rajesh Kumar Bhuyan ◽  
Arun Kumar Parida
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Entropy Weight ◽  
Order Preference ◽  
Pulse On Time ◽  
Machining Characteristics

The objective of this paper is to find the optimum combination on different machining characteristics during electrical discharge machining process of Al-12%SiC Metal matrix composite. Central composite design (CCD) method is used to investigate the effect of three process parameters such as peak current (Ip), pulse on time (Ton), flushing pressure (Fp) on the four response parameters like Material removal rate (MRR), Tool wear rate (TWR), Radial over cut (ROC) and Surface roughness (SR). The multiple objective problems of machining characteristics are optimized by a combine approach of Technique for order preference by similarity to an ideal solution (TOPSIS) and entropy weight measurement method. The Analysis of Variance (ANOVA) is implemented to identify the statistically significant of the Closeness-coefficient results. Finally confirmation test is conducted to compare the experimental data and the predicted data at its optimum parameter to identify the effectiveness of the proposed method.

Influence of Electrical Discharge Machining Parameters on Surface Roughness in Machining of Al 6061-TiB2/ZrB2 In Situ Metal Matrix Composite

2014 ◽  
Vol 592-594 ◽  
pp. 405-409
Author(s):  
Arumugam Mahamani ◽  
N. Sakthivelon ◽  
Sai Kumar Jetti ◽  
M. Vijay Sekar Reddy ◽  
P. Vamsi Krishna Naidu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Experimental Work ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Homogeneous Distribution

In-situ aluminum matrix composites have good bonding strength and homogeneous distribution of particles, which offer improved mechanical property and wear resistance. Electrical discharge machining is considered as a suitable process for making complicated shape of difficult to machine materials. In this experimental work AA6061-6% TiB2/ZrB2in-situ metal matrix composite was fabricated using flex assisted synthesis. This experimental investigation is focused to study the influence of electrical discharge machining process parameter on surface roughness in machining of the AA6061-6% TiB2/ZrB2composite. Taguchi method and L9orthogonal lay out are applied to conduct the experimental work. Analysis of variance was performed to evaluate the percentage of contribution of each parameter. The analysis of the result indicates that discharge current has strongest influence on the surface roughness. This experimental study helps to select the optimal machining parameter to achieve good surface finish.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

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