Optimization of Machining Parameters in Electro Discharge Machining of Al6061-Cu-SiC-Graphite Metal Matrix Composite

2016 ◽  
Vol 860 ◽  
pp. 61-64 ◽  
Author(s):  
Dinesh Kumar Kasdekar ◽  
Vishal Parashar ◽  
Pradeep Soni
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Stir Casting ◽  
Copper Electrode ◽  
Machining Parameters ◽  
Influence Of Process Parameters ◽  
Hybrid Metal Matrix Composite

The newly fabricated hybrid metal matrix composite of Al 6061 reinforced with wt. % of Cu/Sic/Graphite is prepared by a stir casting route. Electrical discharge machining (EDM) is employed to machine this MMC with copper electrode. The purpose of this study is to investigate the second order mathematical model in terms of machining constraints were developed for Material removal rate prediction. The adequacy of the model on MRR has been established with a statistical analysis of variance (ANOVA) to investigate the influence of process parameters and their interactions. Further this model is processed with help of Genetic Algorithm (GA) to find out the optimum machining parameters. The best result for maximum MRR using GA are carried out to show a good agreement with the predicted results.

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 of Tensile Property of Aluminium SiC Metal Matrix Composite

2015 ◽  
Vol 766-767 ◽  
pp. 252-256 ◽  
Author(s):  
A. Siddique Ahmed Ghias ◽  
B. Vijaya Ramnath
Keyword(s):  
Composite Material ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Matrix Material ◽  
Chemical Properties ◽  
High Strength ◽  
Stir Casting ◽  
The Matrix ◽  
Hybrid Metal Matrix Composite

The composite material is a combination of two or more materials with different physical and chemical properties. The composite has superior characteristics than those individual components. A hybrid composite is the one which contains at least three materials. When the matrix material is a metal, the composite is termed as metal matrix composites (MMC). The MMC is a composite material with two constituent parts, one being a metal. The other material may be another metal, ceramic or fiber. Among all the MMC’s, Aluminium is the most widely used matrix material due to its light weight, high strength and hardness. This paper deals with the fabrication and mechanical investigation of hybrid metal matrix composite Al - SiC. The fabrication is done by stir casting by adding the required quantities of additives into the stirred molten Aluminium. The results show significant effect of mechanical properties such as tensile strength, yield stress and flexural strength. The internal structure of the composite is observed using Scanning electron microscope (SEM) and found that are formation of pores in them.

scholarly journals Microstructure evaluation, thermal and mechanical characterization of hybrid metal matrix composite

2018 ◽  
Vol 25 (6) ◽  
pp. 1187-1196 ◽  
Author(s):  
Shyam Lal ◽  
Sudhir Kumar ◽  
Zahid A. Khan
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Casting Process ◽  
Xrd Analysis ◽  
Stir Casting ◽  
Al 7075 ◽  
Dta Analysis ◽  
Hybrid Metal Matrix Composite ◽  
7075 Alloy

AbstractIn this paper, an inert gas assisted electromagnetic stir casting process is adapted for manufacturing a cast hybrid metal matrix composite (MMC) using Al2O3 and SiC particulates as a hard phase reinforcement in Al 7075 alloy metal matrix. Four different samples containing 5, 10, 15 and 20 wt% of Al2O3 and SiC with Al 7075 alloy composites were fabricated. The characterizations for all the samples were carried out through optical microstructure, scanning electron microscopy (SEM) fractograph, X-ray diffraction (XRD) analysis, differential thermal analysis (DTA) analysis and mechanical properties. The results revealed that the particles are uniformly distributed in the matrix. No peaks of Al4C3 were found. There is negligible loss of material in the composite. The tensile strength and microhardness of the hybrid composite are higher by 65.7% and 13.5%, respectively, when compared to its cast metal matrix Al 7075 alloy.

Hybrid EDM and Grinding Hard Materials Using a Metal Matrix Composite Electrode

Volume 3 ◽  
2004 ◽  
Author(s):  
Kuen Ming Shu ◽  
Hung Rung Shih ◽  
Wen Feng Lin ◽  
G. C. Tu
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Composite Electrode ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Mold Material ◽  
Tungsten Carbides

Electrical discharge machining (EDM) has been shown to be a versatile method for machining difficult-to-work materials including heated-treated steels, tungsten carbides and various conductive ceramics. However, low machining efficiency is one of the main EDM disadvantages. The topic of how to reduce machining time and maintains reasonable accuracy has always been of research interest. The main object of the present work was to develop an electrical discharge machining and grinding (EDMG) methodology to remove the re-solidified layer through the grinding induced by a metal matrix composite electrode prior to the re-solidified layer solidification. A metal matrix composite (Cu/SiCp) electrode, with an electroless pretreatment of Cu coating on SiCp to enhance bonding status between Cu and SiCp, with a rotating device was made and employed to study the EDMG technology. Machinabilities of mold material, HPM50 mold steel and P20 WC/Co, were investigated by the combined technologies of EDMG. The machined surfaces of these materials were examined by scanning electron microscopy (SEM) and their surface roughness measured by a profile meter. From the experimental results, it was found that higher material removal rate and lower surface roughness can be achieved when suitable electrode rotating speed, SiCp size and working current are chosen. In addition, the surface roughness of both materials could be improved as compared with that following the EDM process.

Optimization of Machining Parameters on Turning of Hybrid Metal Matrix Composite

2013 ◽  
Vol 315 ◽  
pp. 113-116 ◽  
Author(s):  
T.S. Mahesh Babu ◽  
P.S. Ramkumar ◽  
Nambi Muthukrishnan
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Ratio Method ◽  
Depth Of Cut ◽  
Mechanical And Thermal Properties ◽  
Machining Parameters ◽  
Hybrid Metal Matrix Composite

Hybrid metal matrix composite constitutes a tough metal matrix with reinforcement of at least two ceramic particulates and exhibit superior mechanical and thermal properties. The difficulties in machining metal matrix composites are obtaining good surface finish, consumption of more electrical power, involving excessive cutting forces and greater tool wear as it contain very hard ceramic particulates. This factor restrict the wide spread application of these kind of materials. Hence the study of machining characteristics and the optimization of the cutting parameters are prime importance. In this paper aluminium alloy is taken as metal matrix and the silicon carbide (SiC 10% by wt.) and boron carbide (B4C 5% by wt.) taken as ceramic reinforcement. This material is fabricated in the form of cylindrical rod using stir casting method. Turning operations are carried out in medium duty lathe using poly crystalline diamond (PCD) cutting tool insert. Taguchis design of L09orthogonal array is followed selecting three machining factors namely cutting speed, feed and depth of cut at three levels. Optimal cutting conditions are arrived by Signal-Noise ratio method with respect to surface roughness. The results are validated by (ANOVA) analysis of variance and the percentage of contribution of cutting speed, feed rate and depth of cut for better surface finish are determined and it is found that the vital parameter is feed followed by cutting speed and then by depth of cut.

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