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Abstract

Metal matrix composites (MMC) are finding application in many fields such as aerospace and automobile industries. This is due to their advantages such as light weight and low cost. Among all the available non-traditional machining processes, wire electric discharge machining (WEDM) is found to be a suitable method for producing complex or intricate shapes in composite materials. In this study, an aluminum metal matrix composite (AMMC) with 6% and 8% weight (wt) fraction of Al2O3 is prepared through the stir casting process. The fabricated AMMC specimen is machined using WEDM, considering various process parameters such as wt % of reinforcement, gap voltage (Vg), peak current (IP) wire tension (WT) and dielectric pressure (Pd). Output responses such as the machining rate (MR) and surface roughness (Ra) of the slots are analyzed by conducting L18 mixed orthogonal array (OA) experiments. The experiments are analyzed using techniques for order preference by similarity to ideal solution (TOPSIS) and analysis of variance (ANOVA). Based on the analyses, the optimum combination of process parameters for better MR and Ra is as follows: wt % =  6 gm, Vg = 53 V, Ip = 8 A, WT = 11 g, Pd = 13 bar. The optimum level of process parameters for MR and Ra are 1.5 mm/min and 3.648 µm, respectively. Based on ANOVA, the peak current is found to have a significant influence on MR and Ra. Moreover, based on a scanning electron microscope (SEM) image, the presence of micro-ridges, reinforcement, micro-craters, micro-cracks, recast layers and oxide formation are all analyzed on the surface being machined.

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Authors and Affiliations

T. Mythili
R. Thanigaivelan
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Abstract

The application of micro components in various fields such as biomedical, medical, automobile, electronics, automobile and aviation significantly improved. To manufacture the micro components, different techniques exist in the non-traditional machining process. In those techniques, electrochemical micromachining (ECMM) exhibits a unique machining nature, such as no tool wear, non-contact machining process, residual stress, and heat-affected zone. Hence, in this study, micro holes were fabricated on the copper work material. The sodium nitrate (NaNO₃) electrolyte is considered for the experiments. During the experiments, magnetic fields strength along with UV rays are applied to the electrolyte. The L₁₈ orthogonal array (OA) experimental design is planned with electrolyte concentration (EC), machining voltage (MV), duty cycle (DC) and electrolyte temperature (ET). The optimization techniques such as similarity to ideal solution (TOPSIS), VlseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR) and grey relational analysis (GRA) were employed to find the optimal parameter combinations. The entropy weight method is used to assess the weight of responses such as MR and OC. The optimal combination using TOPSIS, VIKOR and GRA methods shows the same results for the experimental runs 8, 9 and 7, and the best optimal parameter combination is 28 g/l EC, 11 V MV, 85 % DC and 37°C ET. Based on the analysis of variance (ANOVA) results, electrolyte concentration plays a significant role by contributing 86 % to machining performance. The second and least contributions are DC (3.86 %) and ET (1.74 %) respectively on the performance. Furthermore, scanning electron microscope (SEM) images analyses are carried out to understand the effect of magnetic field and heated electrolyte on the work material.
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Authors and Affiliations

K.G. Saravanan
R. Thanigaivelan
M. Soundarrajan

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