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Cryogenic treatment analysis of electrodes in wire electric discharge machining of squeeze casted Al2024/Al2O3/W composite

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Abstract

Peculiar characteristics of squeeze casted hybrid aluminum matrix composites (AMCs) enable it as an appropriate candidate for various manufacturing applications but also make their machining challenging. For that reason, wire electric discharge machining (WEDM) has been preferred over conventional machining processes for the cutting squeeze casted Al2024/Al2O3/W hybrid composite in this study. The presence of nanoparticles in the material affects the machining performance of wire electrodes. Therefore, molybdenum and zinc-coated wires have been chosen, and cryogenic treatment has been applied to improve their machining performance. To analyze the effects of cryogenic treatment, the machining efficiency of cryogenic treated (CT) wire has been compared with non-treated (NT) wire. Besides wire type, four key input variables including pulse duration (TON), wire feed rate (FR), wire runoff speed (SW), and wire tension (TW) have also been optimized to improve the imperative response measures including cutting speed (CS), surface roughness (SR), and kerf width (KW). Microstructural analysis of NT wire depicts a high concentration of micro-voids, micro-cracks, and deep craters, while the surface of CT wire has been observed relatively fine after the machining. Comparative analysis of both wire electrodes has declared that CT wire yields 26.96% and 15.10% superior results for CS and SR respectively, and 6.92% deprived results for KW than NT wire. Grey relational analysis (GRA) has been practiced for multi-objective optimization and presented TON = 3 μs, FR = 13 m/min, SW = 11 m/min, and TW = 10 g as an optimal set of input variables to achieve 75.1% and 72.5% overall results with NT and CT wire, respectively.

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Abbreviations

WEDM:

Wire electric discharge machining

AMC:

Aluminum matrix composite

TON :

Pulse duration

FR :

Wire feed rate

SW :

Wire runoff speed

TW :

Wire tension

TOFF :

Pulse off time

CS :

Cutting speed

SR :

Surface roughness

KW :

Kerf width

I:

Discharge current

V:

Gap voltage

SEM:

Scanning electron microscope

CT wire:

Cryogenic treated zinc-coated brass wire

NT wire:

Non-cryogenic treated zinc-coated brass wire

UTS:

Ultimate tensile strength

RSM:

Response surface methodology

ANOVA:

Analysis of variance

GRA:

Grey relational analysis

GRG:

Grey relational grade

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Funding

This research work was supported in part by the Seed Fund for Basic Research in HKU (Grant No. 201906159001) and in part by ITF project (PRP/068/20LI).

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Systems Engineering, The University of Hong Kong, 8/F, Haking Wong Building, Pok Fu Lam, Hong Kong

    Muhammad Huzaifa Raza & Ray Y. Zhong

  2. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Muhammad Asad Ali & Nadeem Ahmad Mufti

  3. Department of Industrial Engineering, University of Engineering and Technology, Taxila, 47080, Pakistan

    Waseem Tahir

  4. Department of Industrial Engineering, College of Engineering and Architecture, Al-Yamamah University, Riyadh, 11512, Saudi Arabia

    Naveed Ahmad

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  1. Muhammad Huzaifa Raza
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  2. Muhammad Asad Ali
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  5. Nadeem Ahmad Mufti
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Contributions

Conceptualization, Methodology, Writing original draft: Muhammad Huzaifa Raza. Conceptualization, Data curation, Investigation and visualization: Muhammad Asad Ali. Resources, Investigation and Experimentation: Waseem Tahir. Supervision, Review and editing: Ray Y. Zhong. Review and editing: Nadeem Ahmad Mufti, Naveed Ahmad.

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Correspondence to Muhammad Huzaifa Raza.

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Raza, M.H., Ali, M.A., Tahir, W. et al. Cryogenic treatment analysis of electrodes in wire electric discharge machining of squeeze casted Al2024/Al2O3/W composite. Int J Adv Manuf Technol 116, 1179–1198 (2021). https://doi.org/10.1007/s00170-021-07521-5

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