An Effort for Identifying Suitable Machining Range During Drilling of a Novel Al-Based Composite Using Electric Discharge Machine

Keywords: Drilling, EDM, MMC, Quality characteristics, RSM

Abstract

Various aluminium-based metal matrix composites (MMCs) have recently attracted significant interest and increased popularity. This is because of its’ outstanding mechanical properties, which makes it a very popular material since it has various applications in industries that need strong yet lightweight materials with high strength. Researchers have made great progress in the mechanical properties of Al-based composites. In any case, it becomes imperative to improve the mechanical characteristics of the given material on demand. The current work aims at producing these aluminium-based MMC and, subsequently, precise machined EDM. It is an uncommon machining process typically known to produce tough materials of any arbitrary geometry. EDM is a technique that involves the fine-tuning of the electrode material, pulse length, and pulse current to yield the best results without causing much damage to the workpiece and maintaining its mechanical strength. Lastly, the research comprises an elaborate discussion on the optimum process parameters and experimental results about the effective manufacture of superior strength aluminium-based composites as well as their accurate electro-discharge machining. These results provide valuable information on making and machine metals for various technical uses across construction, mechanical engineering and electronics manufacturing industries.

References

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Jain, A., & Singh, B. (2019a). Heat-Affected zone investigation during the laser beam drilling of hybrid composite using statistical approach. Arabian Journal for Science and Engineering, 45(2), 833–848. https://doi.org/10.1007/s13369-019-04162-5

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Kumar, H., Manna, A., & Kumar, R. (2018). Modeling and desirability approach-based multi-response optimization of WEDM parameters in machining of aluminium metal matrix composite. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(9). https://doi.org/10.1007/s40430-018-1368-1

Kumar, J., Singh, D., Kalsi, N. S., Sharma, S., Mia, M., Singh, J., Rahman, M. A., Khan, A. M., & Rao, K. V. (2021). Investigation on the mechanical, tribological, morphological and machinability behavior of stir-casted Al/SiC/Mo reinforced MMCs. Journal of Materials Research and Technology, 12, 930–946. https://doi.org/10.1016/j.jmrt.2021.03.034

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Ferreira, S. L., Bruns, R. E., Ferreira, H. S., Matos, G. D., David, J. M., Brandão, G. C., Da Silva, E., Portugal, L. A., Reis, P. S. D., Souza, A. S., & Santos, W. N. L. D. (2007). Box-Behnken design: An alternative for the optimization of analytical methods. Analytica Chimica Acta, 597(2), 179–186.

https://doi.org/10.1016/j.aca.2007.07.011

Gudipudi, S., Selvaraj, N., Subbu, S. K., & Chilakalapalli, S. P. R. (2021). A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity. Journal of Micromanufacturing, 5(1), 5–20. https://doi.org/10.1177/25165984211063308

Jain, A., & Singh, B. (2019a). Heat-Affected zone investigation during the laser beam drilling of hybrid composite using statistical approach. Arabian Journal for Science and Engineering, 45(2), 833–848. https://doi.org/10.1007/s13369-019-04162-5

Jain, A., & Singh, B. (2019b). Analysis of heat affected zone (HAZ) during micro-drilling of a new hybrid composite. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 234(2), 620–634. https://doi.org/10.1177/0954406219877911

Kumar, A., Grover, N., Manna, A., Kumar, R., Chohan, J. S., Singh, S., Singh, S., & Pruncu, C. I. (2021). Multi-Objective optimization of WEDM of aluminium hybrid composites using AHP and genetic algorithm. Arabian Journal for Science and Engineering, 47(7), 8031–8043. https://doi.org/10.1007/s13369-021-05865-4

Kumar, H., Manna, A., & Kumar, R. (2018). Modeling and desirability approach-based multi-response optimization of WEDM parameters in machining of aluminium metal matrix composite. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(9). https://doi.org/10.1007/s40430-018-1368-1

Kumar, J., Singh, D., Kalsi, N. S., Sharma, S., Mia, M., Singh, J., Rahman, M. A., Khan, A. M., & Rao, K. V. (2021). Investigation on the mechanical, tribological, morphological and machinability behavior of stir-casted Al/SiC/Mo reinforced MMCs. Journal of Materials Research and Technology, 12, 930–946. https://doi.org/10.1016/j.jmrt.2021.03.034

Lu, X., Yu, P., Li, W., Hayat, M. D., Yang, F., Singh, H., Song, W., Qu, X., Xu, Y., & Cao, P. (2020). High-performance Ti composites reinforced with in-situ TiC derived from pyrolysis of polycarbosilane. Materials Science and Engineering: A, 795, 139924. https://doi.org/10.1016/j.msea.2020.139924

Mallick, A., Setti, S. G., & Sahu, R. K. (2023). Centrifugally cast functionally graded materials: Fabrication and challenges for probable automotive cylinder liner application. Ceramics International, 49(6), 8649–8682.

https://doi.org/10.1016/j.ceramint.2022.12.148

Myers, R. H., Montgomery, D. C., & Anderson-Cook, C. M. (2018). Response Surface Methodology: Process and Product Optimization Using Designed SiCnp/Al6082 aluminium matrix composites prepared by squeeze casting combined with stir casting. Journal of Materials Processing Technology, 283, 116699. https://doi.org/10.1016/j.jmatprotec.2020.116699

Published
2023-12-30
How to Cite
Jain, A., Kumar, C. S., & Shrivastava, Y. (2023). An Effort for Identifying Suitable Machining Range During Drilling of a Novel Al-Based Composite Using Electric Discharge Machine. International Journal of Experimental Research and Review, 36, 327-346. https://doi.org/10.52756/ijerr.2023.v36.030
Section
Articles