Prediction of kerf width and surface roughness of Al6351 based composite in wire-cut electric discharge machining using mathematical modelling
Authors:
- Hariharan Sree Ram,
- Marimuthu Uthayakumar,
- Shanmugam Suresh Kumar,
- Sundaresan Thirumalai Kumaran,
- Brian Azzopardi,
- Kinga Korniejenko
Abstract
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.
- Record ID
- CUT83d29618e1b14481867e2d2a0d3ca61e
- Publication categories
- ;
- Author
- Journal series
- Materials, ISSN , e-ISSN 1996-1944, Biweekly
- Issue year
- 2022
- Vol
- 15
- No
- 3
- Pages
- [1-28]
- Article number
- 1102
- Other elements of collation
- fot.; rys.; tab.; wykr.; Bibliografia (na s.) - 27-28; Bibliografia (liczba pozycji) - 29; Oznaczenie streszczenia - Abstr.; Numeracja w czasopiśmie - Vol. 15, Iss. 3, Spec. Iss.
- Substantive notes
- Special Issue: Advances in Wear and Corrosion Resistance of Composite Materials
- Keywords in English
- electric discharge machining (EDM), composite properties, Al6061 composite, mathematical modelling, surface roughness (SR), kerf width
- ASJC Classification
- DOI
- DOI:10.3390/ma15031102 Opening in a new tab
- URL
- https://www.mdpi.com/1996-1944/15/3/1102 Opening in a new tab
- Related project
- E-mobilność oraz zrównoważone materiały i technologie. . Project leader at PK: , ,
- Language
- eng (en) English
- License
- Score (nominal)
- 140
- Score source
- journalList
- Score
- Publication indicators
- Additional fields
- Indeksowana w: Web of Science, Scopus
- Uniform Resource Identifier
- https://cris.pk.edu.pl/info/article/CUT83d29618e1b14481867e2d2a0d3ca61e/
- URN
urn:pkr-prod:CUT83d29618e1b14481867e2d2a0d3ca61e
* presented citation count is obtained through Internet information analysis, and it is close to the number calculated by the Publish or PerishOpening in a new tab system.