scholarly journals Experimental Investigation of Wire-EDM Machining of Low Conductive Al-SiC-TiC Metal Matrix Composite

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1188
Author(s):  
Goutham Murari V.P. ◽  
Selvakumar G. ◽  
Chandrasekhara Sastry C.
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Material Removal ◽  
Deionized Water ◽  
Ideal Solution ◽  
Powdered Mixture ◽  
Pulse On Time ◽  
Pulse Off Time

The application of metal matrix composites (Al-SiC-TiC) in aerospace and defense industries have surged in the areas of hull safety, aviation fins, and closure units. The close to ideal solution for generating powdered mixture availing ball milling, for processing of a metal matrix composite of size 24 × 24 × 5.95 cm3 and composition of 75% Al, 10% SiC, and 10% TiC weight composition is 10:1 ball weight ratio, ball size of 8 mm, rotation speed of 250 rpm, and milling time of 4 h. The powdered mixture is compressed to pellet, sintered for two hours, and further silver coated in a physical vapor deposition setup to surge its electrical conductivity for ease of material removal. To obtain a perfect fit and finish, wire electrical discharge machining cycle has been carried out to machine the component under deionized water and oil + wax + paraffin dielectric mediums in 8 A peak current, 0.45 µs pulse on time, and 45 pulse off time as close to ideal solution, obtained by the technique for the order of preference by similarity to the ideal solution (TOPSIS) analysis. A surge is ascertained in kerf width, material removal rate, and surface roughness in oil + wax + paraffin environment in correlation with deionized water by 0.99–12.78%, 0.18–33.97%, and 2.15–36.86% respectively. The surface morphological study indicates a 32.28%, 42.57%, and 45.73% surge in residual compressive stress, surface roughness and corrosion resistance in oil + wax + paraffin dielectric medium in correlation to deionized water.

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.

Investigation on Machining of Hybrid Metal Matrix Composite

2019 ◽  
Vol 969 ◽  
pp. 846-851
Author(s):  
Anil Kumar Bodukuri ◽  
Kesha Eswaraiah ◽  
V. Pradeep
Keyword(s):  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Advanced Materials ◽  
Matrix Composites ◽  
Hybrid Metal Matrix Composites ◽  
Hybrid Metal Matrix Composite ◽  
Pulse On Time ◽  
Pulse Off Time

Hybrid metal matrix composites (HMMC) are advanced materials which are not simply depicting in improvement of mechanical properties but also on characteristics of machinability for thorny shapes to machine. Electric discharge machining (EDM) shows a potential technique for machining hybrid metal matrix composites. An investigation is done on hybrid metal matrix composite for response parameters like MRR, TWR by conducting a range of experiments with choosing typical process parameters such as peak current, tool lift, pulse-on time and pulse-off time.

Microstructural Characterization of Wire Electro Discharge Machined Tungsten Carbide Cobalt Metal Matrix Composite

2011 ◽  
Vol 383-390 ◽  
pp. 3223-3228 ◽  
Author(s):  
V. Muthuraman ◽  
R. Ramakrishnan
Keyword(s):  
Tungsten Carbide ◽  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Matrix Composite ◽  
Electric Discharge ◽  
Metal Matrix ◽  
Critical Parameters ◽  
Matrix Composites ◽  
Pulse On Time ◽  
Pulse Off Time

Tungsten carbide - Cobalt (WC-Co) reinforced metal matrix composites are most commonly used as tool and die materials. The machining of WC- Co metal matrix composites is usually done by wire electric discharge machining. However during WEDM of WC-Co samples possibility of defects and electrolyzation is high. Also coating of Cu-Zn tool electrode on machined surface and void space takes place, thereby affecting material integrity. Analyzing the microstructures can remarkably reveal the identification, location, extent and criticality of the defects. In this study WC-Co metal matrix composite was wire electric discharge machined with two critical parameters, pulse on time and delay time. The machined samples were analyzed using micrographs, scanning electron microscope, EDAX and the results tabulated. It was found, that lower pulse-on time and medium pulse-off time leads to less rapid quenching and subsequent improvement in surface finish, less craters, voids. This prevents potential sites for defect and weakening of material by filling with cu-zinc particles for unbounded tungsten particle.

Examination on Surface Roughness in EDM of Aluminium 6061 Reinforced with 5% SiC Using Design Experiments

2015 ◽  
Vol 813-814 ◽  
pp. 526-530
Author(s):  
S. Bharanikumar ◽  
S. Arul
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Metal Matrix Composite ◽  
Current Pulse ◽  
Analysis Of Variance ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Taguchi’S Method ◽  
Pulse On Time ◽  
Design Experiments

This paper presents a prediction and evaluation of surface roughness based on Taguchi’s method and the analysis of variance (ANOVA). The experiments were conducted on aluminium 6061 reinforced with 5% SiC to study the surface roughness under various cutting conditions. The objective was to establish a correlation between current, pulse on time flushing pressure with the surface roughness in the metal matrix composite (MMC). The correlation was obtained by multi-variable linear regression and compared with the experimental results.

Experimental Investigation during Micro-Milling of Hybrid Al6063 MMC Reinforced with SiC and ZrO2

2019 ◽  
Vol 33 ◽  
pp. 1-9
Author(s):  
P. Tripathy ◽  
K.P. Maity
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Micro Milling

The experimental investigation of process characteristics while performing micro-milling on hybrid aluminium metal matrix composite is discussed in this article. High Speed Steel micro end mill cutters are used for machining of micro-slots on Al6063 metal matrix composite reinforced with zirconia and silicon carbide. The tools are also treated cryogenically at -196°C using liquid nitrogen with a holding time of 24 hours. For this investigation, machining parameters like feed rate, cutting speed and depth of cut are considered as the process parameters. The effect of the process parameters on the material removal rate and surface roughness for hybrid metal matrix composite are analyzed. In addition, tools wear for untreated and cryo-treated single tempered tools are also investigated. The output responses i.e., material removal rate and surface roughness of cryo-treated tools exhibit better results than untreated tool due to increase in strength, hardness and wear resistance.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

scholarly journals Experimental Exploration of Hybrid Metal Matrix Composite using Abrasive Water Jet Machining

2019 ◽  
Vol 9 (2) ◽  
pp. 1872-1875
Author(s):  
Barath M ◽  
◽  
Rajesh S ◽  
Duraimurugan P ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Water Pressure ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Force Microscopy ◽  
Business Applications ◽  
Hybrid Metal Matrix Composite

The abrasive mixed waterjet was with success utilized to chop several materials together with steel, metal and glass for a spread of business applications. This work focuses on surface roughness of hybrid metal matrix composite (AA6061, Al2O3, B4C). Machining was applied by AWJM (Abrasive Waterjet Cutting) at completely different parameters Water pressure, Traverse speed, Abrasive flow and stand-off distance. The reinforced composite was analyzed exploitation FE SEM (Field Emission Scanning lepton Microscope) and distribution of reinforced was studied by AFM (Atomic Force Microscopy). For optimum results surface roughness was calculated.

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