scholarly journals Investigating the Material Removal Rate Parameters in ECM for Al 5086 Alloy-Reinforced Silicon Carbide/Flyash Hybrid Composites by Using Minitab-18

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
Bhiksha Gugulothu ◽  
P. S. Satheesh Kumar ◽  
Bathula Srinivas ◽  
Alapati Ramakrishna ◽  
S. Vijayakumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Experimental Tests ◽  
Stir Casting ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Casting Method

This study explained about machining parameters of Al5086/Flyash/Sic hybrid metal matrix composites by the Taguchi technique. Al5086 reinforced in SiC (5–10 wt %) and 8% weight of flyash are retained as constants. The specimens are prepared with the help of the stir casting method. The material removal rate was examined by electrochemical machining under various parameters such as feed rate (0.15–0.30 mm/min), voltage (10–20 V), and electrolyte concentration (20–35 g/litre). Taguchi’s L16 orthogonal array was selected for design of experiments (DOEs), and 16 experimental tests were conducted to examine the effect of the selected machining parameters employed to identify the best optimal levels and also to investigate the effect of electrochemical machining parameters on MRR determined by Minitab-18.

An Orthogonal Experimental Study of WEDM-HS of Particle-Reinforced 6061 Al Matrix Composites with 20-Vol% Al2O3

2014 ◽  
Vol 563 ◽  
pp. 21-24 ◽  
Author(s):  
Jiang Wen Liu ◽  
Yong Zhong Wu
Keyword(s):  
Pulse Duration ◽  
Material Removal Rate ◽  
Duty Cycle ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Al Matrix Composites ◽  
Al Matrix

An investigation has been made into the machining feasibility when wire electro-discharge machining with an extremely high travelling speed of wire electrode (WEDM-HS) has been employed to process particle-reinforced 6061 Al matrix composites with 20-vol% Al2O3 (20ALO). And in this study, for the water based emulsion is used as working liquid, there exists an electrochemical effect. And thus, the EDM spark can operate under a relatively large spark gap size condition, and this would be helpful for the removal of the loosen particles and the machined debris. In this study, the material removal rate (MRR) has been examined. Since there are many factors that can influence the MRR during the wire electro-discharge machining process, in order to determine which factor has the most significant effect on the MRR and to obtain the optimal machining parameters, the relative importance of the various machining parameters on material removal rate was analysed by employing an orthogonal design. The results of the orthogonal analysis show that to obtain a high MRR for WEDM-HS machining of 20ALO materials, the duty cycle has the most significant effect on the MRR among current, pulse duration and duty cycle. And the impact of significance for the different factors follows the sequence of duty cycle > current > pulse duration. And under the experiment condition of this study, a duty cycle of 1:4, a current of 5A and a pulse duration of 32μs is the best arrangement for the MRR.

scholarly journals Prediction of Surface Roughness and Material Removal Rate in Electrochemical Machining Using Taguchi Method

2017 ◽  
Vol 12 (4) ◽  
pp. 72-80 ◽  
Author(s):  
Abbas Fadhil Ibrahim
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Maintenance Cost ◽  
Process Conditions ◽  
Machining Parameters

Electrochemical machining is one of the widely used non-conventional machining processes to machine complex and difficult shapes for electrically conducting materials, such as super alloys, Ti-alloys, alloy steel, tool steel and stainless steel.  Use of optimal ECM process conditions can significantly reduce the ECM operating, tooling, and maintenance cost and can produce components with higher accuracy. This paper studies the effect of process parameters on surface roughness (Ra) and material removal rate (MRR), and the optimization of process conditions in ECM. Experiments were conducted based on Taguchi’s L9 orthogonal array (OA) with three process parameters viz. current, electrolyte concentration, and inter-electrode gap. Signal-to-noise (S/N), the analysis of variance (ANOVA) was employed to find the optimal levels and to analyze the effect of electrochemical machining parameters on Ra and MRR. The surface roughness of the workpiece was decreased with the increase in current values and electrolyte concentration while causing an increase in material removal rate. The ability of the independent values to predict the dependent values (R2) were 87.5% and 96.3% for mean surface roughness and material removal rate, respectively.

A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

Effect of valency on material removal rate in electrochemical machining of aluminium

2008 ◽  
Vol 202 (1-3) ◽  
pp. 398-401 ◽  
Author(s):  
S.K. Mukherjee ◽  
S. Kumar ◽  
P.K. Srivastava ◽  
Arbind Kumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Fabrication and Characterization of A356-Basalt Ash-Fly Ash Composites Processed by Stir Casting Method

2017 ◽  
Vol 25 (3) ◽  
pp. 209-214 ◽  
Author(s):  
G. Venkatachalam ◽  
A. Kumaravel
Keyword(s):  
Fly Ash ◽  
Impact Strength ◽  
Hybrid Composites ◽  
Cost Effective ◽  
Weight Fraction ◽  
Stir Casting ◽  
Matrix Composites ◽  
Casting Method ◽  
The Matrix

This paper presents the characterization of A356 composite reinforced with fly ash and basalt ash produced by stir casting method. Aluminium metal matrix composites (AMC) are used in wide variety of applications such as structural, aerospace, marine, automotive etc. Stir casting is cost effective manufacturing process and it is useful to enhance the attractive properties of AMCs. Three sets of hybrid AMC are prepared by varying the weight fraction of the reinforcements (3% basalt + 7% fly ash, 5% basalt + 5% fly, 7% basalt + 3% fly ash). The effect of reinforcements on the mechanical properties of the hybrid composites such as hardness, tensile, compressive and impact strength were studied. The obtained results reveal that tensile, compressive and impact strength was increased when weight fraction of fly ash increased, whereas the hardness increases when weight fraction of the basalt ash increased. Microscopic study reveals the dispersion of the reinforcements in the matrix.

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