This work aims at providing an insight on the area of predicting the outputs of machining of Al6351 based composites using WEDM based on the hardness of the material using mathematical modelling and developing equation for the prediction of kerf width and surface roughness for a new material using functional equations developed. Wire electric discharge machining (WEDM) was identified to be the best option for the machining of these difficult-to-machine composites. This led to the identification of non-conventional machining processes where the tool and workpiece will not have physical contact. The conventional machining process was observed to be time-consuming and costly for the machining of these materials due to frequent tool change leading to increased non-productive time. But the machining of these composites poses a huge challenge to be faced by researchers and identifying the behavior of a newly developed composite for a specific machining process is a big challenge for present-day researchers.
The identification of lighter materials that can bear increased loads is an area of material research in the present scenario. This has led to intense research in the area of composite materials which are easy to manufacture, having higher strength-to-weight ratio and development and modifications can be carried out at a faster rate than conventional materials. Growing competitions and variations in customer requirements have led to development of quicker and newer products that meet customer requirements and provide customer delight in the marketplace. 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.Ī challenge faced by present-day industry is to manufacture lightweight and durable materials at low cost to markets. The validation results show an average variation of 8.17% for kerf width and 11.27% for surface roughness. 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 developed model has been validated by conducting similar set of experiments in Al6351-5% SiC-1% B 4C hybrid composite. 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.
Therefore, identifying the kerf width and surface roughness are important criteria for the dimensional accuracy of the final product. Al6351 composites was observed to be extensively used in nuclear applications. To overcome the challenges of machining complex shapes, wire electric discharge machining (WEDM) was developed. Non-conventional machining, especially electric discharge machining (EDM), is found to be a good machining option for meeting the required outputs. 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.
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