https://orcid.org/0000-0002-8560-6073
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ABSTRACT
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.
Acknowledgments
The authors gratefully acknowledge the Department of Mechanical Engineering, NIT Silchar, for providing the essential resources to experiment.
Disclosure statement
No potential conflict of interest was reported by the author(s).
List of abbreviations
| Adj MS | = | Adjusted mean squares |
| Adj SS | = | Adjusted sum of squares |
| ANOVA | = | Analysis of variance |
| DF | = | Degree of freedom |
| DOE | = | Design of experiment |
| GV | = | Gap voltage |
| Kf | = | Kerf width |
| MMC | = | Metal matrix composites |
| MRR | = | Material removal rate |
| MT | = | Machining time |
| OEC | = | Overall evaluation criteria |
| QC | = | Quality characteristics |
| R2 (adj) | = | R squared (adjusted) |
| SEM | = | Scanning electron microscope |
| SR | = | Surface roughness |
| VRR | = | Volume removal rate |
| WEDM | = | Wire electro discharge machining |
| wt.% | = | Weight percentages |
List of symbols
| λc | = | Cut-off length |
| Al/SiC | = | Aluminum/Silicon carbide |
| B4C | = | Boron carbide |
| Ip | = | Peak current |
| Ton | = | Pulse-on time |
| Toff | = | Pulse-off time |
| V | = | Voltage |
| WC | = | Tungsten carbide |
| ZrO2 | = | Zirconium dioxide |
| ZrSiO4 | = | Zirconium silicate |