Abstract
This research put forth an effort to produce AA5083 (Al-4.4 Mg-0.7 Mn-0.15 Cr)-12 wt.% MoO3 composite via the stir casting (SC) process, and the effects of process parameters such as pulse on time (TON), pulse off time (TOFF), and current (I) on the wire electrical discharge machining (WEDM) characteristics such as metal removal rate (MRR) and surface roughness (SR) were investigated using the Taguchi method. Numerous unconventional machining methods are accessible to machine MMCs; among that, WEDM is a significant method. ANOVA was utilized to identify the suitable parameters to obtain maximum MRR and least SR. From the analysis, it is clear that TON 120 (μs), TOFF 50 (μs), and I 3 (A) are the noteworthy parameters to acquire maximum MRR and TON 100 (μs), TOFF 40 (μs), and I 3 (A) are the noteworthy parameters to acquire least SR. ANOVA results for MRR showed that TOFF is the extreme inducing factor with the percentage contribution of 27.92% tracked by TON and I with the percentage contribution of 12.09% and 5.07%, respectively. ANOVA results for SR showed that TOFF is the extreme inducing factor with the percentage contribution of 60.33% tracked by TOFF and I with the percentage contribution of 12.31% and 0.33%, respectively.
Highlights
Composite materials exhibit better strength, good toughness, less weight, wear opposition resistance, and less cost
metal removal rate (MRR) was calculated via weight difference of workpiece before and after the wire electrical discharge machining (WEDM) process by using the following formula: MRR (Wa − Wb)/t, where Wa and Wb are the weights of the workpiece before and after the WEDM process and “t” is the machining time in minutes. e surface roughness (SR) measurement on the machined surface was done via Mitutoyo surftest SJ-210
Results and Discussion e effect of EDM parameters on SR and MRR was studied via the Taguchi method. e TON, TOFF, and I were selected as parameters, and MRR and SR were considered as output
Summary
Composite materials exhibit better strength, good toughness, less weight, wear opposition resistance, and less cost. E properties such as lightweight, excellent strength, and opposition to wear are Advances in Materials Science and Engineering needed for aeronautics and automotive sectors. Is leads to the growth of AMCs with each probable aluminum alloy as matrix strengthened with numerous reinforcements to attain the explicitly needed properties [6]. SC method was extremely concerned to improve the mechanical behaviour and reinforcement of various alloy materials for strengthening of harder particles [13]. Traditional machining methods such as turning and milling are not appropriate for machining composite materials. Erefore, nontraditional machining process such as WEDM is utilized to machine the composite material [15]. More ANOVA tests were utilized to predict the appropriate parameters
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