<abstract xmlns="http://www.w3.org/1999/xhtml">

In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement. The machining experiments were conducted by varying the input parameters such as voltage (V<italic>s</italic>), wire feed rate (F<italic>w</italic>), current (I<italic>p</italic>), pulse on time (ON<italic>T</italic>) and pulse off time (OFF<italic>T</italic>), on wire breakage. The effect of voltage level and wire breakage frequency was analysed. The parameter combinations for machining the slot of size 5 mm width and 10 mm height with high machining rate (MR) and less surface roughness (R<italic>a</italic>) were analysed using the CRiteria Importance Through Intercriteria Correlation (CRITIC) and simple additive weighting (SAW) methods. The wire breakage frequency is lesser at minimum peak current. The optimal parameter combination for higher MR and lower R<italic>a</italic> is found to be at 30 V, 7 mm/min, 30 A, 120 μs (ON<italic>T</italic>) and 70 μs (OFF<italic>T</italic>). Analysis of variance (ANOVA) is performed to understand the significant factors affecting the WEDM process. ANOVA results predict that wire feed rate and voltage contribute 47.82% and 21.23%, respectively, to MR; and pulse on time shows a 23.06% influence on surface roughness. Scanning electron microscopy (SEM) was used to ascertain the pattern of wire breakage in WEDM, and based on the results obtained from employing this technique, it is inferred that the erosion and breakage of the wire are not instantaneous and that a cone shape is formed on the either portion of the wire.
</abstract>

In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement. The machining experiments were conducted by varying the input parameters such as voltage (Vs), wire feed rate (Fw), current (Ip), pulse on time (ONT) and pulse off time (OFFT), on wire breakage. The effect of voltage level and wire breakage frequency was analysed. The parameter combinations for machining the slot of size 5 mm width and 10 mm height with high machining rate (MR) and less surface roughness (Ra) were analysed using the CRiteria Importance Through Intercriteria Correlation (CRITIC) and simple additive weighting (SAW) methods. The wire breakage frequency is lesser at minimum peak current. The optimal parameter combination for higher MR and lower Ra is found to be at 30 V, 7 mm/min, 30 A, 120 μs (ONT) and 70 μs (OFFT). Analysis of variance (ANOVA) is performed to understand the significant factors affecting the WEDM process. ANOVA results predict that wire feed rate and voltage contribute 47.82% and 21.23%, respectively, to MR; and pulse on time shows a 23.06% influence on surface roughness. Scanning electron microscopy (SEM) was used to ascertain the pattern of wire breakage in WEDM, and based on the results obtained from employing this technique, it is inferred that the erosion and breakage of the wire are not instantaneous and that a cone shape is formed on the either portion of the wire.

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Department of Mechanical and Automation Engineering

Materials Science-Poland

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement....

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Publié en ligne: 30 déc. 2022

Pages: 12 - 26

DOI: https://doi.org/10.2478/msp-2022-0030

Mots clés
zinc wire, microstructure, WEDM, alumina, current

© 2022 P. R. Kannan et al., published by Sciendo

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Publié en ligne: 30 déc. 2022

Pages: 12 - 26

DOI: https://doi.org/10.2478/msp-2022-0030

Mots clészinc wire, microstructure, WEDM, alumina, current

© 2022 P. R. Kannan et al., published by Sciendo

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Mots clés
zinc wire, microstructure, WEDM, alumina, current