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Effect of different reinforcements in wire electric discharge machining of various geometrical profiles in metal matrix composites

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Abstract

In this study three different geometrical profiles with same perimeter were fabricated in aluminum metal matrix composite (AMMCs) using wire electric discharge machining (WEDM). AMMCs containing Al6061 as matrix and 10% alumina (Al2O3), 10% silicon carbide (SiC) and mixture of 5% Al2O3 and 5% SiC as reinforcements were fabricated by stir casting method. The basic objective of this study is to develop response surface methodology (RSM) based second order regression model to analyze the effect of various input parameters on cutting velocity (CV) and surface roughness (SR) during WEDM of triangular, circular, and square profiles of same perimeter. Effect of pulse-on time (Ton = 30–50 µs), pulse-off time (Toff = 6–12 µs), current (I = 1–5 A) and geometrical profiles on CV and SR have been investigated using response surface plots. Parametric analysis reveals that increase of current from 1 to 5 A at Ton = 40 µs, Toff = 12 µs increases the CV by 115% in all the three composites. Similarly, increase of Toff from 6 to 12 µs at Ton = 40 µs and I = 1 A reduces the SR by more than 35% in all composites. Multiobjective optimization using composite desirability (CD) approach shows that optimal results are obtained for triangular profiles and at optimal input parameters SR reduces by 21%, 24.19% and 33.39% respectively for alumina, silicon carbide and hybrid composite. Energy dispersive spectroscopy (EDS) analysis and SEM analysis were carried out to investigate the variation in elemental composition and surface morphology of machined surfaces respectively.

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Abbreviations

WEDM:

Wire electric discharge machine

AMMC:

Aluminum metal matrix composite

ANOVA:

Analysis of variance

MRR:

Material removal rate

GRA:

Grey relational analysis

TOPSIS:

Technique for order of preference by similarity to ideal solution

BBD:

Box–Behken design

RSM:

Response surface method

SEM:

Scanning electron microscopy

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Acknowledgements

The All India Council for Technical Education's (AICTE) 2019-20 Research Promotion Scheme (File No. 8-104/FDC/RPS(POLICY-1)/2019-20) funding help is gratefully acknowledged by the authors.

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  1. Mechanical Engineering Department, Madan Mohan Malaviya University of Technology, Gorakhpur, Uttar Pradesh, India

    Dhirendra Pratap Singh & Sanjay Mishra

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DPS: conceived of the presented idea. He conducted the experiments and performed the computations. DPS: wrote the manuscript with the support of SM. SM: supervised the findings of this work. All authors discussed the results and contributed to the final manuscript.

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Correspondence to Sanjay Mishra.

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Singh, D.P., Mishra, S. Effect of different reinforcements in wire electric discharge machining of various geometrical profiles in metal matrix composites. Int J Interact Des Manuf 18, 351–373 (2024). https://doi.org/10.1007/s12008-023-01477-4

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