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

The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiC<sub>p</sub>). Machinability of such alloys by traditional methods is challenging due to higher tool wear and surface roughness. The objective of research...

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Autores principales:	Deepak Doreswamy, Anupkumar M. Bongale, Marcin Piekarski, Arunkumar Bongale, Satish Kumar, Danil Yurievich Pimenov, Khaled Giasin, Krzysztof Nadolny
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	Wire-Electrical Discharge Machining (Wire-EDM) material removal rate wire speed aluminium composite silicon carbide particles taguchi method Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
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spelling	oai:doaj.org-article:abb4e6dcd73041c99e42a59e347331bf2021-11-11T17:59:54ZOptimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite10.3390/ma142164201996-1944https://doaj.org/article/abb4e6dcd73041c99e42a59e347331bf2021-10-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/21/6420https://doaj.org/toc/1996-1944The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiC<sub>p</sub>). 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 SiC<sub>p</sub> reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (T<sub>on</sub>), wire-speed (W<sub>s</sub>), voltage (I<sub>v</sub>) and pulse-off time (T<sub>off</sub>) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L<sub>16</sub> 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, I<sub>v</sub>, T<sub>off</sub>, T<sub>on</sub> and W<sub>s</sub>, 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% SiC<sub>p.</sub> The results also indicated reinforcing SiC<sub>p</sub> 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 (?<sup>2</sup>—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-SiC<sub>p</sub> (upto 8 wt. %) alloy by wire-EDM industries.Deepak DoreswamyAnupkumar M. BongaleMarcin PiekarskiArunkumar BongaleSatish KumarDanil Yurievich PimenovKhaled GiasinKrzysztof NadolnyMDPI AGarticleWire-Electrical Discharge Machining (Wire-EDM)material removal ratewire speedaluminium compositesilicon carbide particlestaguchi methodTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6420, p 6420 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Wire-Electrical Discharge Machining (Wire-EDM) material removal rate wire speed aluminium composite silicon carbide particles taguchi method Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	Wire-Electrical Discharge Machining (Wire-EDM) material removal rate wire speed aluminium composite silicon carbide particles taguchi method Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Deepak Doreswamy Anupkumar M. Bongale Marcin Piekarski Arunkumar Bongale Satish Kumar Danil Yurievich Pimenov Khaled Giasin Krzysztof Nadolny Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
description	The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiC<sub>p</sub>). 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 SiC<sub>p</sub> reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (T<sub>on</sub>), wire-speed (W<sub>s</sub>), voltage (I<sub>v</sub>) and pulse-off time (T<sub>off</sub>) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L<sub>16</sub> 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, I<sub>v</sub>, T<sub>off</sub>, T<sub>on</sub> and W<sub>s</sub>, 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% SiC<sub>p.</sub> The results also indicated reinforcing SiC<sub>p</sub> 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 (?<sup>2</sup>—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-SiC<sub>p</sub> (upto 8 wt. %) alloy by wire-EDM industries.
format	article
author	Deepak Doreswamy Anupkumar M. Bongale Marcin Piekarski Arunkumar Bongale Satish Kumar Danil Yurievich Pimenov Khaled Giasin Krzysztof Nadolny
author_facet	Deepak Doreswamy Anupkumar M. Bongale Marcin Piekarski Arunkumar Bongale Satish Kumar Danil Yurievich Pimenov Khaled Giasin Krzysztof Nadolny
author_sort	Deepak Doreswamy
title	Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
title_short	Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
title_full	Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
title_fullStr	Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
title_full_unstemmed	Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite
title_sort	optimization and modeling of material removal rate in wire-edm of silicon particle reinforced al6061 composite
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/abb4e6dcd73041c99e42a59e347331bf
work_keys_str_mv	AT deepakdoreswamy optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT anupkumarmbongale optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT marcinpiekarski optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT arunkumarbongale optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT satishkumar optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT danilyurievichpimenov optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT khaledgiasin optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite AT krzysztofnadolny optimizationandmodelingofmaterialremovalrateinwireedmofsiliconparticlereinforcedal6061composite
_version_	1718431961888849920

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

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