Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash)
IntroductionWire-electric discharge machining (WEDM) possesses multiple benefits over traditional production approaches; it allows for the precise processing of complex and rigid particulate-reinforced composite materials. Aluminium alloys have found widespread applications in surgical components, s...
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Frontiers Media S.A.
2025-01-01
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fmech.2024.1526344/full |
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| author | Jayavelu Udaya Prakash Charles Sarala Rubi Sunder Jebarose Juliyana Sachin Salunkhe Sachin Salunkhe H. B. Özerkan Lenka Cepova |
| author_facet | Jayavelu Udaya Prakash Charles Sarala Rubi Sunder Jebarose Juliyana Sachin Salunkhe Sachin Salunkhe H. B. Özerkan Lenka Cepova |
| author_sort | Jayavelu Udaya Prakash |
| collection | DOAJ |
| description | IntroductionWire-electric discharge machining (WEDM) possesses multiple benefits over traditional production approaches; it allows for the precise processing of complex and rigid particulate-reinforced composite materials. Aluminium alloys have found widespread applications in surgical components, shipbuilding, aircraft, automobiles, and inhaling gas cylinders for scuba diving, due to its good strength, and light weight properties.MethodsThe main aim of this investigation is to optimize different process variables for LM6/B4C/Fly ash particle reinforced hybrid composites using WEDM to attain performance metrics such as maximum material removal rate (MRR) and minimal surface roughness (SR). Taguchi’s L27 orthogonal array (OA) matrix and Grey Relational Analysis (GRA) were used.Results and DiscussionAccording to ANOVA, the two variables with the most significant impact on MRR and SR are gap voltage and reinforcement percentage, with respective impacts of 29.59% and 20.69%. When the composite is machined, the following process variables work best: GV of 30 V, Ton of 10 µs, Toff of 2 µs, WF of 4 m/min, and R of 6%. A low gap voltage causes the erosion to rise and the MRR to increase. However, SR will also increase which is undesirable, so optimum gap voltage values are required for WEDM. |
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| institution | Kabale University |
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| language | English |
| publishDate | 2025-01-01 |
| publisher | Frontiers Media S.A. |
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| series | Frontiers in Mechanical Engineering |
| spelling | doaj-art-9231cb3ce6cc45598046b1515645507a2025-01-23T06:56:33ZengFrontiers Media S.A.Frontiers in Mechanical Engineering2297-30792025-01-011010.3389/fmech.2024.15263441526344Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash)Jayavelu Udaya Prakash0Charles Sarala Rubi1Sunder Jebarose Juliyana2Sachin Salunkhe3Sachin Salunkhe4H. B. Özerkan5Lenka Cepova6Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, IndiaDepartment of Physics, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, IndiaDepartment of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, IndiaDepartment of Biosciences, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, IndiaDepartment of Mechanical Engineering, Faculty of Engineering, Gazi University, Ankara, TürkiyeDepartment of Mechanical Engineering, Faculty of Engineering, Gazi University, Ankara, TürkiyeDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, Ostrava, CzechiaIntroductionWire-electric discharge machining (WEDM) possesses multiple benefits over traditional production approaches; it allows for the precise processing of complex and rigid particulate-reinforced composite materials. Aluminium alloys have found widespread applications in surgical components, shipbuilding, aircraft, automobiles, and inhaling gas cylinders for scuba diving, due to its good strength, and light weight properties.MethodsThe main aim of this investigation is to optimize different process variables for LM6/B4C/Fly ash particle reinforced hybrid composites using WEDM to attain performance metrics such as maximum material removal rate (MRR) and minimal surface roughness (SR). Taguchi’s L27 orthogonal array (OA) matrix and Grey Relational Analysis (GRA) were used.Results and DiscussionAccording to ANOVA, the two variables with the most significant impact on MRR and SR are gap voltage and reinforcement percentage, with respective impacts of 29.59% and 20.69%. When the composite is machined, the following process variables work best: GV of 30 V, Ton of 10 µs, Toff of 2 µs, WF of 4 m/min, and R of 6%. A low gap voltage causes the erosion to rise and the MRR to increase. However, SR will also increase which is undesirable, so optimum gap voltage values are required for WEDM.https://www.frontiersin.org/articles/10.3389/fmech.2024.1526344/fullhybrid compositesstir castingTaguchi’s DOEWEDMceramic particles |
| spellingShingle | Jayavelu Udaya Prakash Charles Sarala Rubi Sunder Jebarose Juliyana Sachin Salunkhe Sachin Salunkhe H. B. Özerkan Lenka Cepova Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) Frontiers in Mechanical Engineering hybrid composites stir casting Taguchi’s DOE WEDM ceramic particles |
| title | Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) |
| title_full | Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) |
| title_fullStr | Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) |
| title_full_unstemmed | Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) |
| title_short | Optimization of WEDM process parameters for machining hybrid composites (LM6/B4C/Fly Ash) |
| title_sort | optimization of wedm process parameters for machining hybrid composites lm6 b4c fly ash |
| topic | hybrid composites stir casting Taguchi’s DOE WEDM ceramic particles |
| url | https://www.frontiersin.org/articles/10.3389/fmech.2024.1526344/full |
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