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.

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.

An Orthogonal Experimental Analysis of WEDM-HS of Al2O3 Particle-Reinforced Aluminum Alloy 6061 with 10-Vol% Al2O3

2014 ◽  
Vol 910 ◽  
pp. 61-64 ◽  
Author(s):  
Jiang Wen Liu ◽  
Yong Zhong Wu
Keyword(s):  
Aluminum Alloy ◽  
Pulse Duration ◽  
Material Removal Rate ◽  
Duty Cycle ◽  
Experimental Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

In wire electro-discharge machining with an extremely high travelling speed of wire electrode (WEDM-HS), the emulsion is used as working liquid. Because there exists a functional electrolyte, the EDM spark can operate under a relatively large spark gap size condition, and this would facilitate the removal of machined debris. An investigation has been made into the machining feasibility when WEDM-HS has been employed to process Al2O3particle reinforced aluminum alloy 6061 with 10-vol% Al2O3(10ALO). And the material removal rate (MRR) has been examined in this study. Since there are many factors that can influence the MRR in the WEDM-HS process, in order to determine which is the most important factor and to optimize the machining parameters, the relative importance of the various machining parameters on material removal rate was established by utilizing an orthogonal experimental analysis. The results of the analysis suggest that to achieve a high MRR for particulate reinforced aluminum 6061 with 10-vol% Al2O3, the duty cycle is the most influential factor among current, pulse duration and duty cycle. And the impact of the different factors follows the sequence of duty cycle > current > pulse duration.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

Determination of Material Removal Rate and Radial Overcut in Electro Discharge Machining of AISI 304 Using Dimensional Analysis

2016 ◽  
Vol 852 ◽  
pp. 160-165 ◽  
Author(s):  
Munmun Bhaumik ◽  
Kalipada Maity ◽  
Kasinath Das Mohapatra
Keyword(s):  
Dimensional Analysis ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Aisi 304 ◽  
Radial Overcut ◽  
Electro Discharge Machining ◽  
Work Material

Electro discharge machining (EDM) is a most commonly used machining process among all the non-conventional machining process which removes materials via electrical and thermal energy. The primary goal of EDM is to get more material removal rate (MRR) with lower radial overcut (ROC). Normally, the responses are predicted using empirical models which are limited to only machining parameters and they do not consider the effects of work material properties on the process performance. Therefore in this study, a model has been developed including machining parameter as well as thermo-physical property of work material. In this investigation, a semi-empirical model has been established for the material removal rate (MRR) and radial overcut (ROC) by adopting the dimensional analysis technique. Dimensional analysis is a technique of dimensions and a mathematical technique that deals with the physical quantities concerned with the experiments to formulate a model for the response in terms of response control parameters as well as some physical properties of the materials. Buckingham’s л theorem is a main theorem in dimensional analysis and it is a signification of Rayleigh’s method of dimensional analysis. The theory is applied to gather each and every variable presenting the problem in a number of the dimensionless products. For this study, the thermo-physical properties viz. density, thermal conductivity and coefficient of thermal expansion and machining parameters like peak current, pulse on time, gap voltage and duty cycle are considered as input factor. AISI 304 stainless steel used as work material and Tungsten carbide is used as tool material for this investigation.

Experimental Study on Dry WEDM Finishing

2010 ◽  
Vol 455 ◽  
pp. 190-193 ◽  
Author(s):  
Tong Wang ◽  
Feng Qiu ◽  
C.Q. Wang ◽  
G.Z. Zhang ◽  
Xiao Cun Xu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Pulse Duration ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Dry Wedm

Comparing with conventional WEDM in emulsion, dry finishing of high-speed WEDM (HS-WEDM) has advantages such as higher material removal rate, better surface roughness and straightness. Authors have presented a new procedure as gas-liquid combined multiple cut, in which roughing is processed in dielectric liquid, and semi-finishing is in liquid or gas, while finishing is in gas. For better understanding the effect of machining parameters on surface roughness and cutting speed in dry finishing, a L25(56) Design was implemented. The analysis of variance shows that the effect of pulse duration on surface roughness is of high significance, and peak current is of significance respectively, and the effect of no load worktable feed on cutting speed is high significant.

scholarly journals Effect of Micro-EDM Parameters on Material Removal Rate of Nonconductive ZrO2 Ceramic

2013 ◽  
Vol 465-466 ◽  
pp. 1329-1333 ◽  
Author(s):  
Abdus Sabur ◽  
Abdul Moudood ◽  
Mohammad Yeakub Ali ◽  
Mohammad Abdul Maleque
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Carbon Layer ◽  
Machining Process ◽  
Machining Parameters ◽  
Micro Edm ◽  
Machined Surface ◽  
Electro Discharge Machining

Micro-electro discharge machining (micro-EDM) technique, an advanced noncontact machining process, is used for structuring of nonconductive ZrO2 ceramic. In this study copper foil as a conductive layer is adhered on the workpiece surface to initiate the sparks and kerosene is used as dielectric for creation of continuous conductive pyrolytic carbon layer on the machined surface. Voltage (V) and capacitance (C) are considered as the parameters to investigate the process capability of machining parameters in continuous micro-EDM of ZrO2. Different voltage pulses are studied to examine the causes of lower material removal rate (MRR) in micro-EDM of nonconductive ceramics. The results showed that in micro-EDM of ZrO2 MRR increases with the increase of voltage and capacitance initially, but decreases at higher values and no significant materials are removed at capacitances higher than 1nF.

An Orthogonal Experimental Analysis of Electrical Discharge Machining of Particle Reinforced Metal Matrix Composites with Concavo-Convex Electrode

2011 ◽  
Vol 314-316 ◽  
pp. 890-893
Author(s):  
Jiang Wen Liu ◽  
Guang Xue Chen ◽  
Tai Man Yue ◽  
Zhong Ning Guo ◽  
Zi Yao Wan
Keyword(s):  
Material Removal Rate ◽  
Duty Cycle ◽  
Experimental Analysis ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Matrix Composites ◽  
Particulate Reinforced

A new concavo-convex electrode has been designed and employed and it was reported that electrical discharge machining (EDM) of particulate reinforced metal matrix composites with this kind of new electrode can accelerate the debris discharge during machining so that it has a higher material removal rate (MRR) compared to the case where a normal electrode was employed. Since there are many factors that can affect the MRR in the EDM process with the concavo-convex electrode, in order to determine which is the most important factor and to optimize the machining parameters, the relative importance of the various cutting parameters on material removal rate was established using an orthogonal experimental analysis in this study. The results of the analysis suggest that to achieve a high MRR for particulate reinforced aluminum 6061 with 10-vol% Al2O3 (10ALO) or 20vol% Al2O3 (20ALO) using a concavo-convex electrode, the duty cycle is the most influential factor among current, pulse duration and duty cycle.

Sign in / Sign up

Export Citation Format

Share Document