Experimental Study and Optimization of Wire-Electrical Discharge Machined WC-15%Co Metal Matrix Composites

2014 ◽  
Vol 984-985 ◽  
pp. 227-232
Author(s):  
Veluswamy Muthuraman ◽  
Raju Ramakrishnan ◽  
Ponnusamy Sengottuvel ◽  
C. Karthikeyan
Keyword(s):  
Tungsten Carbide ◽  
Metal Matrix Composites ◽  
Analysis Of Variance ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Machining Process ◽  
Cobalt Metal ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Pulse On Time

Wire Electrical discharge Machining plays an important role in the field of hard, difficult to machine materials like metal matrix composites. Machining process must keep pace with material development. For electrically conductive materials wire electro discharge machining is a viable option due to high accuracy, precision, and ability to achieve complex, intricate shaped profiles on even thin works. Due to thermo-electric nature it is a stochastic process in nature. To simplify the difficulty in determining parameters for the improvement of cutting performance and optimization, analysis of variance and regression analysis were made use of. Tungsten carbide cobalt metal matrix composites finds increasing applications in conventional application like tools and dies as well as in developing fields like bio-medical instruments and aero-space industries. In this present work, the problem of parameter selection, optimization for wire electro discharge machining on tungsten carbide-15% cobalt metal matrix composites, a less worked composition has been undertaken. Sodick AQ-427L wire-edm machine was used with a 0.25 diameter zinc coated brass wire electrode, to cut the material. Each experiment done under different cutting conditions of inputs like pulse on time, pulse off time, wire speed and peak current and repeated for three observations and the average was selected. Optimum machining parameter combination for material removal rate was obtained by using the desirability response optimizer function. Analysis of variance, Confirmation experiment was carried and good improvements were obtained.

On the Optimisation Into Wire Electro-Discharge Machining of Al/Al2O3P Composites

2007 ◽  
Author(s):  
N. G. Patil ◽  
P. K. Brahmankar ◽  
L. G. Navale
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Kerf Width ◽  
Feed Speed ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Machining Parameter

Non-traditional process like wire electro-discharge machining (WEDM) is found to show a promise for machining metal matrix composites (MMCs). However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as nonelectrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/Al2O3p). Taguchi orthogonal array was used to study the effect of combination of reinforcement, current, pulse on-time, off-time, servo reference voltage, maximum feed speed, wire speed, flushing pressure and wire tension on kerf width and cutting speed. Reinforcement percentage, current, on-time was found to have significant effect on cutting rate and kerf width. The optimum machining parameter combinations were obtained for cutting speed and kerf width separately.

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.

Effect of process parameters on the electrical discharge machining of aluminum metal matrix composites through a response surface methodology approach

2016 ◽  
Vol 23 (2) ◽  
pp. 145-154
Author(s):  
V. Balasubramaniam ◽  
N. Baskar ◽  
Chinnaiyan Sathiya Narayanan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix Composites ◽  
Current Pulse ◽  
Process Parameters ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Matrix Composites ◽  
Pulse On Time

AbstractThis work presents the multiobjective optimization of machining parameters during the electrical discharge machining (EDM) of aluminum (Al)-silicon carbide (SiC) metal matrix composites (MMC). The process parameters considered were current, pulse on-time, dielectric flushing pressure, and SiC particles. A copper rod was used as an electrode. An Al-SiC MMC with Al 6061 as matrix and SiC particles having three different sizes (i.e., 15, 25, and 40 μm) were used as workpieces. The experiments were planned using design of experiments through response surface methodology (RSM). The mathematical models were developed to predict the better performance measures such as the material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR), and cylindricity (CY). The desirability approach in RSM was performed for optimization. It was found that the MRR increases with increasing peak current, pulse on-time, flushing pressure, and particle size. The EDM parameters are to be analyzed for the MRR, EWR, SR, and CY. The best one is proposed for validation.

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