Finite element analysis of wire EDM process parameters on performance characteristics of Al–SiC hybrid composite with micro and nano reinforcements

Abstract

Aluminum Hybrid Composites (AHC) microchannels find extensive applications in aerospace, refrigeration and air conditioning (RAC), microelectronics, automotive, biomedical, and marine industries due to their improved mechanical properties. The combination of lower density, high hardness, elevated thermal and electrical conductivity, superior elasticity, and heightened oxidizing ability at low temperatures makes machining aluminum hybrid composites challenging through orthogonal methods in an open environment. Therefore, it is imperative to investigate the impact of various machining conditions to determine optimal parameter values for microchannel fabrication in aluminum hybrid composite materials. This study aims to identify the ideal machining parameters for Al–SiC micro-SiC nano hybrid composites using wire electrical discharge machining. Four distinct process parameters (pulse on time, gap voltage, wire tension, and wire feed rate) and two response parameters (material removal rate (MRR) and surface roughness (SR)) were considered for process optimization. Additionally, finite element modeling was conducted for the aforementioned process, and the results were compared with experimental outcomes. Single-variable optimization yielded maximum MRR at 125 tons (μs), 25 SV (volt), 12 WT (kgf), and 2 WFR (m/min), and minimum SR at 125 tons (μs), 10 SV (volt), 12 WT (kgf), and 4 WFR (m/min). Single-variable optimization for simulations resulted in maximum MRR at 125 tons (μs), 40 SV (volt), 4 WT (kgf), and 6 WFR (m/min), and minimum SR at 110 tons (μs), 10 SV (volt), 12 WT (kgf), and 2 WFR (m/min). Precise modeling aids in minimizing unnecessary machining, enabling exploration of a broader range of experimental results, thereby promoting environmentally friendly and sustainable machining practices.