Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite

Materials

Danil Yurievich Pimenov¹  Anupkumar M. Bongale²  Satish Kumar³  Arunkumar Bongale³  Deepak Doreswamy⁴  Krzysztof Nadolny⁵  Marcin Piekarski⁶  Khaled Giasin⁷ 

[1] Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, 454080 Chelyabinsk, Russia;Department of Computer Science and Information Technology, Symbiosis Institute of Technology, Symbiosis International (Deemed University), Lavale, Pune 412115, Maharashtra, India;Department of Mechanical Engineering, Symbiosis Institute of Technology, Symbiosis International (Deemed University), Lavale, Pune 412115, Maharashtra, India;Department of Mechatronics Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal 576104, India;Department of Production Engineering, Faculty of Mechanical Engineering, Koszalin University of Technology, Racławicka 15-17, 75-620 Koszalin, Poland;Mathematic and Physics Department, Gdansk University of Technology, G. Narutowicza 11/12, 80-233 Gdansk, Poland;School of Mechanical and Design Engineering, University of Portsmouth, Portsmouth PO1 3DJ, UK;

关键词: Wire-Electrical Discharge Machining (Wire-EDM);    material removal rate;    wire speed;    aluminium composite;    silicon carbide particles;    taguchi method;   

DOI  :  10.3390/ma14216420

来源: DOAJ

【 摘 要 】

The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiC_p). Machinability of such alloys by traditional methods is challenging due to higher tool wear and surface roughness. The objective of research is to investigate the machinability of SiC_p reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (T_on), wire-speed (W_s), voltage (I_v) and pulse-off time (T_off) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L₁₆ orthogonal arrays. The MRR obtained at different experiments are analyzed using statistical tools. It is observed that all the chosen process parameters showed significant influence of on the MRR with contribution of 27.39%, 22.08%, 21.32%, 15.76% and 12.94% by I, I_v, T_off, T_on and W_s, respectively. At optimum settings, the Wire-EDM resulted in MRR of 65.21 mg/min and 62.41 mg/min for samples with 4% and 8% SiC_p. The results also indicated reinforcing SiC_p upto 8% showed marginally low influence on MRR. Microstructural investigation of the cut surface revealed the presence of craters with wave pattern on its surface. The top surface of the crater is featured by the recast layers connecting adjacent craters. Further, the statistical model is developed using linear regression to predict the MRR (?²—73.65%) and its predicting accuracy is verified by the confirmation trials. The statistical model is useful for predicting the MRR for different settings of the process parameters. The optimized settings can be used to improve the machining productivity by increasing the MRR while machining of Al6061-SiC_p (upto 8 wt. %) alloy by wire-EDM industries.

【 授权许可】

Unknown