Wire Electrical Discharge Machining of a Hybrid Composite: Evaluation of Kerf Width and Surface Roughness

Yıl 2016, Cilt: 21 Sayı: 1, 243 - 258, 17.06.2016

Abdil Kuş , Ali Motorcu , Ergün Ekici

https://doi.org/10.17482/uujfe.21303

Cited By: 7

Öz

In this study, the machinability characteristics of Al/B4C-Gr hybrid composite were investigated using wire electrical discharge machining (WEDM). In the experiments, the machining parameters of wire speed, pulse-on time and pulse-off time were varied in order to explaiın their effects on machining performance, including the width of slit (kerf) and surface roughness values (Rz and Rt). According to the Taguchi quality design concept, a L18 (21×32) orthogonal array was used to determine the S/N ratio, and analysis of variance (ANOVA) and the F-test were used to indicate the significant machining parameters affecting the machining performance. From the ANOVA and F-test results, the significant factors were determined for each of the machining performance criteria of kerf, Rz and Rt. The variations of kerf, Rz and Rt with the machining parameters were statistically modeled via the regression analysis method. The optimum levels of the control factors for kerf, Rz and Rt were specified as A1B1C1, A1B1C2 and A1B1C2, respectively. The correlation coefficients of the predictive equations developed for kerf, Rz and Rt were calculated as 0.98, 0.828 and 0.855, respectively.

Anahtar Kelimeler

Wire EDM; kerf; surface roughness; hybrid composite; Taguchi method

KARMA KOMPOZİTİN TEL ELEKTRO EROZYON TEZGÂHINDA İŞLENMESİNDE: KESİM GENİŞLİĞİ VE YÜZEY PÜRÜZLÜLÜĞÜNÜN DEĞERLENDİRİLMESİ

Öz

Bu çalışmada, Al/B4C-Gr karma kompozitin tel elektro erozyon tezgâhında işlenebilirlik karakteristikleri araştırılmıştır. Deneylerde; kesim genişliği (kerf) ve yüzey pürüzlülük değerlerini (Rz ve Rt) içeren işleme performansı etkilerinin incelenmesinde tel hızı, vurum süresi ve vurum ara süresi işleme parametreleri olarak seçilmiştir. Taguchi kalite tasarım konseptine göre, S/N oranını tanımlamak için bir L18 (21×37) ortogonal dizi ve işleme performansını etkileyen anlamlı işleme parametrelerini belirlemek için varyans analizi (ANOVA) ve F-testi kullanılmıştır. ANOVA ve F-testi sonuçlarından,  işleme performansı kriterleri kerf, Rz ve Rt'nin her biri için anlamlı faktörler belirlendi. İşleme parametreleri ile kerf, Rz ve Rt'nin değişimleri regresyon analizi metodu yardımıyla istatistiksel olarak modellenmiştir. Kerf, Rz ve Rt için kontrol faktörlerinin optimum seviyeleri sırasıyla A1B1C1, A1B1C2 ve A1B1C2 olarak belirlendi. Kerf, Rz ve Rt için geliştirilen tahminsel denklemlerin korelasyon katsayıları sırasıyla 0.98, 0.828 ve 0.855 olarak hesaplanmıştır.

Anahtar Kelimeler

Tel elektro erozyon; kesim genişliği; yüzey pürüzlülüğü; karma kompozit; Taguchi metot

Kaynakça

• Ciftci İ, Turker M, Seker U. (2004) Evaluation of Tool Wear when Machining SiCp-Reinforced Al-2014 Alloy Matrix Composites, Materials and Design, 25, 251255. doi:10.1016/j.matdes.2003.09.019
• Durairaja M, Sudharsun D, Swamynathan N. (2013) Analysis of Process Parameters in Wire EDM with Stainless Steel Using Single Objective Taguchi Method and Multi Objective Grey Relational Grade, Procedia Engineering, 64, 868877. doi:10.1016/j.proeng.2013.09.163
• Fard RK, Afza RA, Teimouri R. (2013) Experimental Investigation, Intelligent Modeling and Multi-Characteristics Optimization of Dry WEDM Process of Al–SiC Metal Matrix Composite, Journal of Manufacturing Processes, 15, 483494. doi:10.1016/j.jmapro.2013.09.002
• Garg RK, Singh KK, Sachdeva A, Sharma VS, Ojha K, Singh S. (2010) Review of Research Work in Sinking EDM and WEDM on Metal Matrix Composite Materials, International Journal of Advanced Manufacturing Technology, 50, 611624. doi:10.1007/s00170-010-2534-5
• Hu HM, Lavernia EJ, Harrigan WC, Kajuch J, Nutt SR. (2001) Microstructural Investigation on B4C/Al-7093 Composite, Materials Science and Engineering: A, 297, 94104. doi:10.1016/S0921-5093(00)01254-5
• Iwai Y, Honda T, Miyajima T, Iwasaki Y, Surappa MK, Xu JF. (2000) Dry Sliding Wear Behavior of Al2O3 Fiber Reinforced Aluminum Composites, Composites Science and Technology, 60, 17811789. doi:10.1016/S0266-3538(00)00068-3
• Kevin Chou YR and Liu J. (2005) CVD Diamond Tool Performance in Metal Matrix Composite Machining, Surface and Coatings Technology, 200, 18721878. doi:10.1016/j.surfcoat.2005.08.094
• Krishnamurthy L, Sridhara BK, Budan DA. (2007) Comparative Study on the Machinability Aspects of Aluminum Silicon Carbide and Aluminum Graphite Composites, Materials and Manufacturing Processes, 22, 903908. doi:10.1080/10426910701451754
• Lahane SD, Rodge MK, Sharma SB. (2012) Multi-response Optimization of Wire-EDM Process using Principal Component Analysis, IOSR Journal of Engineering (IOSRJEN), 2, 3847.
• Lau WS, Yue TM, Lee TC, Lee WB. (1995) Un-conventional Machining of Composite Materials, Journal of Materials Processing Technology, 48, 199205. doi:10.1016/0924-0136(94)01650-P
• Lauwers B, Brans K, Liu W, Vleugels J, Salehi S, Vanmeensel K. (2008) Influence of the Type and Grain Size of the Electro-Conductive Phase on the Wire-EDM Performance of ZrO2 Ceramic Composites, CIRP Annals - Manufacturing Technology, 57, 191194. doi:10.1016/j.cirp.2008.03.089
• Lin Q, Shen P, Qiu, F. Zhang D, Jiang Q. (2009) Wetting of Polycrystalline B4C by Molten Al at 1173–1473K, Scripta Materialia, 60, 960963. doi: 10.1016/j.scriptamat.2009.02.024
• Manna A Bhattacharyya B. (2006) Taguchi and Gauss Elimination Method: A Dual Response Approach for Parametric Optimization of CNC Wire Cut EDM of PRAlSiC MMC, Journal of Advanced Manufacturing Technology, 28, 6775. doi: 10.1007/s00170-004-2331-0
• Montgomery DC. (1991) Taguchi’s Contributions to Experimental Design and Quality Engineering, Design and Analysis of Experiment; John Wiley and Sons, Canada.
• Muthuraman V, Ramakrishnan R. (2012) Multi Parametric Optimization of WC-Co Composites Using Desirability Approac, Procedia Engineering, 38, 33813390. doi:10.1016/j.proeng.2012.06.391
• Patil NG, Brahmankar PK. (2010) Determination of Material Removal Rate in Wire Electro-Discharge Machining of Metal Matrix Composites using Dimensional Analysis, Journal of Advanced Manufacturing Technology, 51, 599610.
• Patil NG, Brahmankar PK. (2010) Some Studies into Wire Electro-Discharge Machining of Alumina Particulate-Reinforced Aluminum Matrix Composites, Journal of Advanced Manufacturing Technology, 48, 537555. doi: 10.1007/s00170-009-2291-5
• Praskash JU, Moorthy TV, Peter JM. (2013) Experimental Investigation on Machinability of Aluminium Alloy (A413)/Flyash/B4C Hybrid Composites Using Wire EDM, Procedia Engineering, 64, 13441353. doi: 10.1016/j.proeng.2013.09.216
• Puhan D, Mahapatra SS, Sahu J, Das L. (2013) A Hybrid Approach for Multi-Response Optimization of Non-Conventional Machining on AlSiCp MMC, Measurement, 46, 35813592. doi: 10.1016/j.measurement.2013.06.007
• Ravikiran A, Surappa MK. (1997) Effect of Sliding Speed on Wear Behavior of A356 Al 30 wt % SiCp MMC, Wear, 206, 3338. doi:10.1016/S0043-1648(96)07341-3
• Ross PJ. (1996) Taguchi Techniques for Quality Engineering. Loss Function, Orthogonal Experiments Parameter and Tolerance Design, McGraw-Hill, New York.
• Rozenek M, Kozak J, Dabrowski L, Lubkowski K. (2001) Electrical Discharge Machining Characteristics of Metal Matrix Composites, Journal of Materials Processing Technology, 109, 367370. doi:10.1016/S0924-0136(00)00823-2
• Rubio JCC, Silva LJ, Leite WO, Panzera TH, Filho SLMR, Davim JP. (2013) Investigations on the Drilling Process of Unreinforced and Reinforced Polyamides using Taguchi Method, Composite Part B, 55, 338344. doi: 10.1016/j.compositesb.2013.06.042
• Saha P, Singha A, Pal SK, Saha P. (2008) Soft Computing Models Based Prediction of Cutting Speed and Surface Roughness in Wire Electro-Discharge Machining of Tungsten Carbide Cobalt Composite, Journal of Advanced Manufacturing Technology, 39, 7484. doi: 10.1007/s00170-007-1200-z
• Saha P, Tarafdar D, Pal SK, Saha P, Srivastava AK, Das K. (2013) Multi-Objective Optimization in Wire-Electro-Discharge Machining of TiC Reinforced Composite through Neuro-Genetic Technique, Applied Soft Computing, 13, 20652074. doi:10.1016/j.asoc.2012.11.008
• Satishkumar D, Kanthababu, M, Vajjiravelu V, Anburaj R, Sundarrajan NT, Arul H. (2011) Investigation of Wire Electrical Discharge Machining Characteristics of Al6063/SiCp Composites, Journal of Advanced Manufacturing Technology, 56, 975986. doi: 10.1007/s00170-011-3242-5
• Shandilya P, Jain PK, Jain NK. RSM and ANN Modeling Approaches for Predicting Average Cutting Speed during WEDM of SiCp/6061 Al MMC, Procedia Engineering, 64, 767774. doi:10.1016/j.proeng.2013.09.152
• Sharma N, Khanna R, Gupta R. (2013) Multi Quality Characteristics of WEDM Process Parameters with RSM, Procedia Engineering, 64, 710719. doi: 10.1016/j.proeng.2013.09.146
• Singh H, Garg R. (2009) Effects of Process Parameters on Material Removal Rate in WEDM, Journal of of Achievements in Materials and Manufacturing Engineering, 32, 7074.
• Tosun N, Cogun C, Tosun G. (2004) A Study on Kerf and Material Removal Rate in Wire Electrical Discharge Machining Based on Taguchi Method, Journal of Materials Processing Technology, 152, 316322. doi:10.1016/j.jmatprotec.2004.04.373
• Vankanti VK, Ganta V. (2014) Optimization of Process Parameters in Drilling of GFRP Composite using Taguchi Method, Journal of Materials Research and Technology, 3, 3541. doi:10.1016/j.jmrt.2013.10.007
• Yan BH, Tsai HC, Huang FY, Lee LC. (2005) Examination of Wire Electrical Discharge Machining of Al2O3p/6061Al Composites, International Journal of Machine Tools and Manufacture, 45, 251259. doi: 10.1016/j.ijmachtools.2004.08.015