scholarly journals An Experimental Investigation on the Material Removal Rate and Surface Roughness of a Hybrid Aluminum Metal Matrix Composite (Al6061/SiC/Gr)

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1449
Author(s):  
Mandeep Singh ◽  
Sthitapragyan Maharana ◽  
Anchal Yadav ◽  
Rasmeet Singh ◽  
Pragyansu Maharana ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Aluminum Metal ◽  
Aluminum Metal Matrix Composite

The objective of this paper was to determine the optimum process parameters of an electric discharge machine while machining a new hybrid aluminum metal matrix composite. In this study, a new hybrid aluminum metal matrix composite was prepared, with silicon carbide and graphite particles used as reinforcements, with the help of the stir casting method. The selected electric discharge machining parameters in this study were peak current (I), voltage (V), pulse-on time (Ton), and tool material, while the response parameters were material removal rate and surface roughness. To machine the fabricated samples, two different types of tool materials (copper and brass) were used as electric discharge machine electrodes, and each had a diameter (Ø) of 12.0 mm. The optimal settings of the electric discharge machining parameters were determined through experiments planned, conducted, and analyzed using the Taguchi (L18) technique. An analysis of variance and confirmatory tests were used to check the contribution of each machining parameter. It was found that the material removal rate increased with the increase in pulse-on time and pulse current, whereas the material removal rate decreased with the increase in voltage. On the other hand, reduced surface roughness could only be achieved when current, voltage, and pulse duration were low. It was also found that the selected electric discharge machining electrodes had a significant effect on both the material removal rate and the surface roughness.

Electric discharge sawing of hybrid metal matrix composites

2015 ◽  
Vol 231 (10) ◽  
pp. 1775-1782 ◽  
Author(s):  
Ravinder Kumar ◽  
Inderdeep Singh
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Debris Accumulation ◽  
Carbon Particles ◽  
Hybrid Metal Matrix Composite ◽  
Sawing Process

Electric discharge sawing process is a novel process for the enrichment of capabilities of electric discharge machining. The process has been developed to cut materials at greater depths where the effect of flushing becomes ineffective. During electric discharge machining at greater depths, ineffective flushing prevents debris and carbon particles from leaving the machining zone and gets accumulated in the sparking zone reducing the spark efficiency. This reduces material removal rate and causes arcing or short circuiting which may damage the workpiece and/or tool surface. In the present experimental endeavor, a new process capable of preventing debris accumulation during machining of slots at large depth and subsequently increasing material removal rate has been developed. In the process, a reciprocating motion is given to the tool blade similar to the power hacksaw blade. An experimental investigation based on central composite design has been conducted on hybrid metal matrix composite to evaluate the effect of input parameters on material removal rate and tool wear rate. It has been found that the electric discharge sawing process is quick and effective as compared to the conventional cutting process.

scholarly journals Comparative Analysis of Machining Characteristics of EDM and ECM during Machining of Ti-6Al-4V

2021 ◽  
Vol 23 (2) ◽  
Author(s):  
Banwait S.S. ◽  
◽  
Sanjay S ◽  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Pulse On Time ◽  
Surface Finish Effect ◽  
Machining Characteristics

The present work explains the machining of Titanium alloy using Electric Discharge Machining & Electro-Chemical Machining. This work aims to analyze the role of Current, Pulse on Time, Voltage and hence optimize the Material Removal Rate and Surface Roughness in Electric Discharge Machining. In the same way, it also aims to analyze the role of Concentration, Feed, and Voltage and optimize the Material Removal Rate and Surface Roughness in Electro-Chemical Machining. The various approaches like Taguchi & Analysis of Variance are executed to study the performance characteristics of the input parameters on the output parameters. The whole work is followed by a validation test and hence confirming the obtained values. Thus, it reveals the acceptability of the model. The work tells that Material Removal Rate and Surface Finish effect is more in Electro-Chemical Machining as compared to Electric Discharge Machining. For Material Removal Rate, Current and Feed are more responsible parameters for Electric Discharge Machining. In the same way; electrolyte concentration and Feed are more responsible parameters for Electro-Chemical Machining respectively.

scholarly journals Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3689
Author(s):  
Thanikodi Sathish ◽  
Vinayagam Mohanavel ◽  
Khalid Ansari ◽  
Rathinasamy Saravanan ◽  
Alagar Karthick ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Stir Casting ◽  
Electric Discharge Machining ◽  
Az61 Magnesium Alloy

Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.

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.

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