Fig 7 - uploaded by Subbarama Kousik Suraparaju
Content may be subject to copyright.
(a) Talysurf surface roughness tester, (b) Video measuring Machine (VMS), (c) Kerf width measurement using VMS.
Source publication
Hybrid nanometal matrix composites (HNMMC) have emerged as a promising material with a broad array of applications in the aerospace, defence and automotive industries due to its remarkable mechanical properties. In this article HNMMC sample prepared by mixing Al-6082 and two reinforcement materials [0.4%Graphene (Gr) and 0.5% Carbon nanotubes (CNT)...
Contexts in source publication
Context 1
... output responses were measured for each experiment and noted in the Table 5. MRR is calculated by measuring the initial and final weight of the sample, machining time. Further, MRR represented in g\min by diving the weight of the material removed with machining time. The Surface roughness is found out with Talysurf measuring device as shown in Fig. 7(a). For any WEDMed sample, precision is one of the primary requirements. To estimate the value of additional tolerance subjected to cutting the kerf width is very important. Kerf width is determined with a video measuring machine (VMS) as shown in Fig. 7b & ...
Context 2
... machining time. The Surface roughness is found out with Talysurf measuring device as shown in Fig. 7(a). For any WEDMed sample, precision is one of the primary requirements. To estimate the value of additional tolerance subjected to cutting the kerf width is very important. Kerf width is determined with a video measuring machine (VMS) as shown in Fig. 7b & ...
Context 3
... output responses were measured for each experiment and noted in the Table 5. MRR is calculated by measuring the initial and final weight of the sample, machining time. Further, MRR represented in g\min by diving the weight of the material removed with machining time. The Surface roughness is found out with Talysurf measuring device as shown in Fig. 7(a). For any WEDMed sample, precision is one of the primary requirements. To estimate the value of additional tolerance subjected to cutting the kerf width is very important. Kerf width is determined with a video measuring machine (VMS) as shown in Fig. 7b & ...
Context 4
... machining time. The Surface roughness is found out with Talysurf measuring device as shown in Fig. 7(a). For any WEDMed sample, precision is one of the primary requirements. To estimate the value of additional tolerance subjected to cutting the kerf width is very important. Kerf width is determined with a video measuring machine (VMS) as shown in Fig. 7b & ...
Similar publications
The current trend in the materials engineering sector is to develop newer materials that can replace the existing materials in various engineering sectors in order to be more and more efficient. Therefore, the present research work is aimed at fabricating and determining the physical, mechanical, and dry sliding wear properties of titanium carbide...
Electrode Discharge Mechanism (EDM) is a manufacturing process using controlled sparks that occur between an electrically conductive workpiece and an electrode in the presence of an insulating liquid. The EDM process is commonly used to manufacture metallic matrix compounds that have wide applications in the railway sectors and the aircraft industr...
Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curve...
Ceramic particle reinforced metal matrix composites (MMCS) have been recognized as a hot research hotspot as a local wear-resistant material for vital parts of mechanical equipment. Fe60 matrix and NbC particle (NbCp) reinforced Fe60 composites(NbCp/Fe60) were produced through vacuum sintering and tested on an MLD-10B Impact Wear Rig. As revealed b...
Over the last few decades, ‘Discontinuously Reinforced Particulate Composites (DRPCs)’ are a popular class of composite materials with considerable challenge in processing, characterization and machinability because of their increased strength-weight ratio, stiffness, specific strength and oxidization when compared to various metals and their alloy...
Citations
... 7,8 Recently, flexible electrode technology has made significant achievements, such as stretchable and self-healing devices. 9,10 The core of these flexible devices is to prepare conductive components (graphene, 11 nano-metal wires, 12 MXene, 13 carbon nanotubes, 14 etc.) uniformly dispersed in a flexible matrix [polydimethylsiloxane (PDMS), 15 polyethylene terephthalate (PET), 16 hydrogel, 17 silica gel, 18 etc.]. Advanced flexible material design and preparation technologies have brought new ideas to the research and development of multifunctional flexible electronic generation, such as posture sensing and energy harvesting technologies. ...
Recently, flexible wearable electronics for human running posture monitoring and human energy harvesting have attracted widespread attention. Hence, we design a mixed type conductive hydrogel based on polyvinyl alcohol, cotton paper, graphite oxide, and MXene, named PCGM hydrogel. Furthermore, the PCGM hydrogel can act as the PCGM-based strain sensor and triboelectric nanogenerator (P-TENG) for running posture monitoring and mechanical energy harvesting. The PCGM-based strain sensor has two sensing linear regions: The pressure sensitivity is 0.0164 kPa−1 in the low pressure region (0–16 kPa), whereas it is 0.002 86 kPa−1 in the high pressure region (16–120 kPa). To achieve comprehensive health monitoring of runners, the PCGM-based strain sensors can be installed on human joints and facial skin to monitor human posture and facial expressions. The PCGM hydrogel can be combined with a polytetrafluoroethylene film to form a P-TENG device for mechanical energy harvesting. The P-TENG maximum output power can reach 135 µW with a 30 MΩ load. The short-circuit current (Isc), open-circuit voltage (Voc), and transfer charge (Qsc) of P-TENG can reach 10.36 µA, 229.85 V, and 49.24 nC, respectively. This research provides an effective approach for human-running motion monitoring by using multifunctional flexible devices.
... They found that the pulse-on time contributed significantly to achieving maximum MRR. Perla, V. R., et al. [17] reported that by mixing Al-6082 with reinforcing materials [0.4% graphite (Gr) and 0.5 % carbon nanotubes (CNT)] in a WEDM process. The processing performance of the obtained HNMMC samples was studied. ...
The newly metal matrix Nano-composite (MMNC) of commercially pure Al reinforced with 0.5 wt.% Al 2 O 3 nanoparticles was prepared by non-contact ultrasonic cavitation method. The high resolution transmission electron micrograph shows uniform distribution and good dispersion of the Al 2 O 3 nanoparticles within the aluminum metal matrix. Wire Electrical discharge machining (WEDM) was employed to machine MMNC with brass wire electrodes. The machining parameter along with characteristics performance characteristics were simultaneously optimized using Taguchi's multi response signal to noise ratio (MRSN) technique and the optimum process parameters have been reported. Moreover, ANOVA technique is used to determine the contribution of input variables for the overall machining performance. This MRSN technique is simple and does not require the help of any software for its implementation.is described in this paper.
... e positive polarity provides a higher MRR. Many researchers [16,17] investigated the WEDM process parameters of Inconel 601 using brass wire. ...
... e aluminium alloy 6082 has superior strength and excellent corrosion resistance properties. is can be found as a structural alloy with superior mechanical properties in the 6000 series [17]. e aluminium alloy 6082 with the dimensions of 180 mm × 100 mm × 10 mm size has been chosen for the WEGM, and the same has been shown in Figure 1. e chemical composition of the material is listed in Table 1 , and the property of aluminium alloy 6082 is listed in Table 2. ...
... In this figure, while increasing the PT ON KF also gradually increased. is is due to the applied energy removed from the material leading to cause more MRR [17]. Figure 8 indicates the effect of WF and PT OFF for KF on the 3D response surface and counterplot. ...
Wire electrical discharge machining (WEDM) is an unconventional machining process that is being extensively used in the aerospace,medical devices, die, tooling, and automotive industries for machining high-hardness materials with conductivity. In the present work, WEDM of aluminium 6082 alloys was carried out since it influences diversified applications in manufacturing industries. The WEDM process includes an extensive number of variables that influence its execution. However, based on the literature survey, three process parameters such as pulse-on time (PTON), pulse-off time (PTOFF), and wire feed (WF) were taken into consideration. The factorial design was used for the selection of parameter levels and arrived at the 27 trails for the machining. The output responses of the WEDM, namely, surface roughness (SR), kerf width (KF), and metal removal rate (MRR) were measured, and its parameter optimization was also carried out to minimize the significant effect on productivity and the quality of components. The measured output response was compared with the predicted response surface methodology (RSM) results; it was found that the SR and KF values decreased with the increase of PTON. The MRR was increased with the increase of PTON.
... The work identified that MOPSO provides a better and quicker optimization when compared to NSGA-II and the optimized results were validated by carrying out experiments which were showing very close results to the evaluated results. Perla et al. [17] carried out investigations on wire EDM for nano hybrid aluminium composite with graphene and carbon nanotube added to Al6082. The investigations were carried out for optimizing surface roughness, material removal rate, and kerf width. ...
... Based on the graphs, the coefficient Equations based on the Brinell hardness (HRB) (13)(14)(15)(16)(17)(18)(19) were obtained for the kerf width. The graph and the equations were generated using graph software and it was targeted to create the simplest method for the prediction. ...
The machining of composite materials has been an area of intense research for the past couple of decades due to its wide range of applications, from automobiles to air crafts or from boats to nuclear systems. Non-conventional machining, especially electric discharge machining (EDM), is found to be a good machining option for meeting the required outputs. To overcome the challenges of machining complex shapes, wire electric discharge machining (WEDM) was developed. Al6351 composites was observed to be extensively used in nuclear applications. Therefore, identifying the kerf width and surface roughness are important criteria for the dimensional accuracy of the final product. The present work aims at predicting the behavior of the two major machining parameters which are kerf width and surface roughness of Al6351 composites in wire EDM by creating a mathematical model using ANOVA for different combinations of the reinforcements and comparing the variations in the coefficients for different combinations of reinforcements. The developed model has been validated by conducting similar set of experiments in Al6351-5% SiC-1% B4C hybrid composite. From the work, it was identified that pulse on time and current are the major contributing factor for kerf width and wire feed rate was observed to be contributing to the surface roughness. The validation results show an average variation of 8.17% for kerf width and 11.27% for surface roughness. The work can be successfully utilized for prediction of the kerf width and surface roughness of the composites manufactured with Al6351 as the base matrix material.
Composites are being used since decades and imparting excellent properties comparatively. It may be used in numerous industries because of its light weight and specific strength. Machinability of these materials is a concerned aspect. Conventional and The composites have been machined using unconventional machining techniques. Conventional methods are less suitable than non-conventional quoting the best surface finish and ability to machine complex parts. This article investigates the suitability of thermo-electric process for the machining of composites for higher surface quality and material removal. It includes the study of machining by die sinking, wire cut, powder mixed electric discharge machine in different matrix based composites along with the variation of reinforcement. Electric Discharge Machining (EDM) finds its suitability in machining of different metal matrix composites (MMC) more than the Polymer Matrix Composite (PMC) and Ceramic Matrix Composites (CMC). Variation in input parameters listed as Pulse duration, Voltage, Peak Current and Polarity is studied to obtain the optimum resulting parameters as Material Removal Rate (MRR), Surface Roughness (SR), Electrode Wear Rate (EWR) and Kerf Width. Material removal in PMC is 16% more in parallel fibre direction than with perpendicular. Low electrical conductance and high hardness of CMCs limits the use of EDM while natural ceramics are found more suitable for machining. Gap voltage, pulse on time and current are found most crucial in machining MMCs while quantifying material removal and surface roughness.
Metal matrix composites (MMCs) are a category of advanced materials that are challenging to process as these contain hard ceramic reinforcement particles that are distributed irregularly. Wire electro discharge machining (WEDM) is an advanced machining process that has the potential to machine hard ceramic reinforcing materials, which are electrically conductive. In this research, the WEDM process is utilized to evaluate the machinability of aluminum (Al) based MMCs. Two different fabricated Al-6063 alloy-based MMCs with silicon carbide (SiC) reinforcement particles of 220 and 600 grit size of 9 weight percentages are considered as the workpiece material. Using an experimental design with a full factorial, three process variables pulse-on time (Ton), pulse-off time (Toff), and peak current (Ip) are used to determine how they affect the on-response measures of machining time (MT), kerf width (Kf), and material removal rate (MRR). After experimentation, ANOVA analysis is applied to find out the most significant factor. ANOVA analysis reveals that Ip is the primary contributor to MT and MRR for Al/SiC (220) and Al/SiC (600) MMCs. However, Ton is the most influential factor for Kf in the case of both the MMCs. Overall evaluation criteria are also applied for the simultaneous study of response measures.
In this investigation, a machinability study of the fabricated aluminium (Al) and magnesium (Mg) based MMCs is done using the Wire-EDM process. Initially, Al and Mg-based MMCs are fabricated with Silicon Carbide (SiC) reinforcements particles by the bottom pouring type stir casting process. After that, successful machining of both Al and Mg-based MMCs is carried out using Wire-EDM. The lowest value of machining time and kerf width for both Al/SiC and Mg/SiC MMCs are observed (0.1732 min, 0.3270 mm) and (0.1980 min, 0.2970 mm) respectively. The highest value of material removal rate 71.6651 mm³/min and 53.1313 mm³/min are achieved correspondingly for the Al and Mg-based MMCs. Overall evaluation criteria (OEC) values are calculated for all machining conditions to find out the mean effect of all process parameters simultaneously. The highest calculated OEC value of 75.00 and 84.45 are observed intended for Al/SiC and Mg/SiC respectively.
In the modern manufacturing era, machining alloys and composite materials enable proper machining methods to get the required shape and dimensions. The usage of alloys and composite materials is increasing in several industries including aerospace, automobile, MEMS, electronics, medical, biomedical, pharmaceutical industries, and so on because of less weight and more strength. Though various methods are available for machining of composites materials and alloys, only electrochemical micro-machining (ECMM) and wire electrical discharge machining (WEDM) are apt for micron-level machining of these materials by complex shapes with good surface quality. This chapter attempts to provide insight into the recent developments in machining of these alloys and composite materials by ECMM and WEDM.
