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.

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.

scholarly journals EVALUATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE IN ELECTRICAL DISCHARGE MACHINING OF AL-ALLOY WITH 10%SIC

2022 ◽  
Vol 23 (1) ◽  
pp. 349-357
Author(s):  
Abbas Fadhil
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Al Alloy ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

Aluminum-based metallic matrix compounds are widely used in industrial and aircraft manufacturing due to their advanced characteristics, such as toughness and high strength resistance to weight ratio, etc. Silicon carbide is an important industrial ceramic and it is the fourth hardest ceramic after diamond, boron nitride, and boron carbide. Owing to its low fracture toughness, it is difficult to machine silicon carbide using traditional machining processes. Electrical discharge machine can machine such materials irrespective of their hardness. Aluminum alloy 6061 and 10% SiC based-metal matrix composite were used as a workpiece that was produced by stir casting. In the experimental investigation, pulse current Pc (10, 20, and 30 A), pulse on (Pon) duration (100, 150, and 200 ?sec), and pulse off (Poff) duration (6, 12, and 24 ?sec) were treated as the input variables. The output responses were surface roughness (SR) and material removal rate (MRR). The best value for surface roughness (Ra) reached (1.032 µm) at Pc (10 A), Pon duration (100 ?sec) and Poff (15 ?sec). Also, the best result for the productivity of the process (MRR) reached (69.49 × 10-3 g/min) at Pc (30 A) Pon, (200 ?sec) and (6 ?sec) Poff. Therefore, the experimental outcomes were optimized for surface roughnes and material removal rate by adding 10% SiC to aluminum alloy 6061. ABSTRAK: Sebatian matrik logam berasaskan aluminium telah digunakan secara meluas dalam industri pembuatan dan pesawat kerana ciri-cirinya yang canggih, seperti ketahanan dan daya rintangan yang tinggi kepada nisbah berat, dan lain-lain. Silikon karbida adalah seramik industri yang penting dan ia merupakan seramik keempat terkuat setelah berlian, boron nitrida dan boron karbida. Disebabkan ketahanan frakturnya yang rendah, adalah sukar bagi menghasilkan mesin silikon karbida menggunakan proses pemesinan tradisional. Mesin pelepasan elektrik mampu menghasilkan mesin menggunakan bahan tersebut tanpa mengira kekerasan. Aloi aluminium 6061 dan komposit matrik logam berasaskan SiC 10% telah digunakan sebagai bahan kerja yang terhasil melalui tuangan kacauan. Melalui penyelidikan eksperimen, detik arus Pc (10, 20, dan 30 A), detik hadir (Pon) berdurasi (100, 150, dan 200 ?sec), dan detik henti (Poff) berdurasi (6, 12, dan 24 ?sec) dirawat sebagai pemboleh ubah input. Respon pengeluaran adalah kekasaran permukaan (SR) dan kadar penyingkiran bahan (MRR). Nilai terbaik bagi kekasaran permukaan (Ra) telah mencapai (1.032 µm) pada Pc (10 A), berdurasi Pon (100 ?sec) dan Poff (15 ?sec). Tambahan, hasil terbaik bagi proses produktiviti (MRR) mencapai (69.49 × 10-3 g/min) pada Pc (30 A) Pon, (200 ?sec) dan (6 ?sec) Poff. Oleh itu, hasil eksperimen dioptimumkan bagi permukaan kasar dan kadar penyingkiran bahan dengan tambahan 10% SiC ke aloi aluminium 6061.

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.

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.

Effects of Pulse Duration and Current on EDM Process of Allegheny Ludlum D2 Tool Steel

2013 ◽  
Vol 315 ◽  
pp. 369-373
Author(s):  
S. Sulaiman ◽  
A.A. Khan ◽  
M.A. Razak ◽  
M.R. Ibrahim ◽  
M.S. Yusof
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Pulse Duration ◽  
Tool Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Edm Process

The purpose of this paper is to study the effect of current on performance of EDM process of Allegheny Ludlum D2 Tool Steel (UNS T30402). The effect of varying the machining parameters on the machining responses such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (Ra) have been investigated. In this study, circular shape of copper was used as an electrode with surface area of 100mm². The experiments were repeated for three different values of pulse duration (100µs, 200µs and 400µs) with combination of three different values of discharge current (12A, 16A and 24A). It was found that the pulse duration and current give significant effect on MRR, EWR and Ra. An increase in the pulse durations causes an increase in the MRR and Ra, but a decrease in the EWR. Meanwhile, the effect of currents on EDM performance shows that the increasing currents led to an increase in the MRR, EWR and Ra.

scholarly journals Experimental Study on the Influence of Tool Electrode Material on Electrochemical Micromachining of 304 Stainless Steel

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2311
Author(s):  
Jianxiao Bian ◽  
Baoji Ma ◽  
Haihong Ai ◽  
Lijun Qi
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloy ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
304 Stainless Steel ◽  
Aluminum Alloy 6061 ◽  
Thin Walled ◽  
Alloy 6061 ◽  
Tungsten Steel

Different cathode materials have different surface chemical components and machining capacities, which may finally result in different machining quality and machining efficiency of workpieces. In this paper, in order to investigate the influence of cathode materials on the electrochemical machining of thin-walled workpiece made of 304 stainless steel, five cylindrical electrodes are used as the target working cathodes of electrochemical machining to conduct experiments and research, including 45# steel, 304 stainless steel, aluminum alloy 6061, brass H62, and tungsten steel YK15. The stray current corrosion, taper, and material removal rate were used as the criteria to evaluate the drilling quality of efficiency of a thin-walled workpiece made of 304 stainless steel. The research results show that from the perspectives of stray current corrosion and taper, aluminum alloy 6061 is an optimal tool cathode, which should be used in the electrochemical machining of thin-walled workpieces made of 304 stainless steel; on the aspect of material removal rate, the 45# steel, 304 stainless steel, and aluminum alloy 6061 present close material removal rates, all of which are higher than that of brass H62 and tungsten steel YK15. Based on comprehensive consideration of both machining quality and machining efficiency, the aluminum alloy 6061 is the best option as the cathode tool in the electrochemical machining of thin-walled workpieces made of 304 stainless steel.

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

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