Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

J Udaya Prakash,S Jebarose Juliyana,G Kalusuraman,G Elias,P Sivaprakasam,Ilhami Colak,Ilhan Garip,Karthikeyan Sathasivam

doi:10.1155/2021/2503673

Abstract

The present study looks into the effect of WEDM process parameters on the material removal rate (MRR) and surface roughness (SR) responses when machining hybrid composites (Al-Si12/boron carbide/fly ash) using the Taguchi technique. Fly ash and boron carbide (B4C) particles were used for reinforcement (3%, 6%, and 9% by weight), and aluminium alloy (Al-Si12) was used as a matrix material. ANOVA was used to find out the importance of machining factors that affect the quality features of the WEDM process, as well as the relative role of input parameters in determining the WEDM process’ responses. The greatest impact on the response is finalised by the signal-to-noise (S/N) ratio response analysis. However, as a last step, a confirmation experiment with the best combination was carried out to predict and validate the accuracy of the observed values. As the pulse on time and reinforcement increases, MRR also increases. As the gap voltage, wire feed, and pulse off time decrease, it increases. SR is increased by increasing the gap voltage, pulse on time, and pulse off time, wire feed, and reinforcement. The maximum MRR of 38.01 mm3/min and the minimum SR of 3.24 μm were obtained using optimal machining conditions.

Highlights

Composite materials are produced by combining two or additional materials in order that they mechanically function as one single entity
The analysis indicates that the Taguchi technique is better suited to solving the stated problem with fewer experiments than a complete factorial design [9]
The method can improve performance characteristics by determining the appropriate parameter settings and lowering the system’s susceptibility to sources of variation

Summary

Introduction

Composite materials are produced by combining two or additional materials in order that they mechanically function as one single entity. The hard phase functions as a reinforcing agent in most composite materials, increasing elastic modulus, while the soft phase serves as a matrix. The advantage of using composites is that they can achieve proved to be beneficial and may end up in a variety of service advantages such as enhanced strength, significantly reduced weight, enhanced wear resistance, and high elastic modulus [1]. Particulatereinforced metal matrix composites (MMCs) possess high stiffness but low strength, as well as outstanding fabricability, less cost, and homogeneity. The traditional reinforcement materials for AMCs are SiC and Al2O3. Because B4C powder is more expensive than SiC and Al2O3, there have been few studies on boron carbide-reinforced MMCs

Methods

Results

Conclusion