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

Deepak Doreswamy,Marcin Piekarski,Anupkumar M Bongale,Danil Yurievich Pimenov,Khaled Giasin,Arunkumar Bongale,Krzysztof Nadolny,Satish Kumar

doi:10.3390/ma14216420

Abstract

The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiCp). 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 SiCp reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (Ton), wire-speed (Ws), voltage (Iv) and pulse-off time (Toff) 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, Iv, Toff, Ton and Ws, 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% SiCp. The results also indicated reinforcing SiCp 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 (𝑅2—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-SiCp (upto 8 wt. %) alloy by wire-EDM industries.

Highlights

Wire-WEDM is a non-conventional machining method in which the removal of material occurs by the repetitive sparks produced between the electrode and the work material in the dielectric medium
The current settings beyond the peak levels result in rapid deposition of the debris at the machining gap which leads to significant influence on the characteristics of dielectric breakdown and affects the material removal [45]
This study investigated the effect of parameters such as I, ton, toff, ws, Iv on machining of 4 wt. % to 8 wt. % silicon carbide particles (SiCp) —Al6061 alloy by wire-EDM

Summary

Introduction

Wire-WEDM is a non-conventional machining method in which the removal of material occurs by the repetitive sparks produced between the electrode and the work material in the dielectric medium. Wire-EDM is extensively used in the industries for producing the complex contours in the electrically conductive materials such as aluminium, copper, brass, titanium and other alloys. The aluminium alloys are popularly used in transport applications (automobiles, aeroplanes and ships) for reducing the fuel consumption and carbon emission. The sector-wise usage is as follows: the transportation industry—23%, building and construction—25%, packaging industries—8%, engineering industries—11% and electrical appliances—12% [1]. This metal possesses low density, good malleability, corrosion resistance and electricity conductivity. Aluminium series material shows excellent mechanical properties and weldability, it finds applications in aircraft fittings, electrical fittings and connectors, camera lens mounts, marines fittings and hardware, couplings, hinge pins, pistons, bike frames, valve parts, etc. [2,3]

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