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Experimental Characterization of Dimensional and Surface Alternation of Straight and Angular Cutting on Self-lubricating Composite: A Wire EDM Approach

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Abstract

Demands on better control over the kerf dimension deviation, surface roughness, and corner accuracy are now on the increase for the two-piece aluminum metal composite mold tools. In this investigation, straight and triangular profile cuts attempted with wire electrical discharge machining (WEDM) on the aluminum 6061 self-lubricating composite-reinforced boron carbide (5–15 vol%) and hexagonal boron nitride particles (10 vol% hBN) fabricated using a stir casting method. Rational video measurement showed an increase in B4C particles reduces kerf width dimension deviation only at TON, TOFF and gap voltage (V) parameters. Optical microscope measurement showed an increase in the corner area inaccuracy increases with both low and high pulse-on duration conditions caused by insufficient material removal and a high order of erosion, respectively. There was a large reduction in corner area inaccuracy with increasing wire feed rate. Surface characteristics were examined using a scanning electron microscope (SEM) and XRD to enable observation of the structural damages and recast layers. Composite with 5% boron carbide showed a re-deposition layer over the machined surface, whereas 15% boron carbide composite went through uneven erosion causing the formation of craters and pits on the cutting surface resulting in higher surface roughness.

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Acknowledgements

The authors would like to express their sincere thanks to the Science and Engineering Research Board (SERB), Government of India, New Delhi, for providing the financial assistance for conducting this research through a Research Grant No. EEQ/2017/000382.

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Authors and Affiliations

  1. Department of Industrial Engineering, CEG Campus, Anna University, Chennai, 600025, India

    A. Gnanavelbabu

  2. Department of Mechanical Engineering, SSN College of Engineering, Chennai, 600110, India

    K. Rajkumar

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Correspondence to K. Rajkumar.

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Gnanavelbabu, A., Rajkumar, K. Experimental Characterization of Dimensional and Surface Alternation of Straight and Angular Cutting on Self-lubricating Composite: A Wire EDM Approach. Arab J Sci Eng 45, 5859–5872 (2020). https://doi.org/10.1007/s13369-020-04596-2

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  • DOI: https://doi.org/10.1007/s13369-020-04596-2

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