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A Review Paper on Machining of Metal Matrix Composite and Optimizing Methods used in Electrical Discharge Machining
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ScienceDirect Materials Today: Proceedings 5 (2018) 24428–24438
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IConAMMA_2017
A Review Paper on Machining of Metal Matrix Composite and Optimizing Methods used in Electrical Discharge Machining Kamlesh Paswana*, Somnath Chattopadhyayab, Alokesh Pramanikc a b
Research Scholar, Department of mechanical engineering, Indian institute of Technology (Indian School of Mines) Dhanbad
Associate professor, Department of mechanical engineering, Indian institute of Technology (Indian School of Mines) Dhanbad c
Lecturer, Department of mechanical engineering, Curtin, University, Australia
Abstract
Electric discharge machining is a non-conventional thermal erosion process. In this article investigation has been done on the effect of different reinforcement (carbides, oxides and nitrides), dielectric (kerosene, distilled water and PMEDM) and methods (RSM and GRA) for machining of MMC materials and optimizing the responses. Variation in responses due to all these factors are properly examined and depicted in figures. Result shows that there are various reinforced materials available and different methods have been developed effectively and many more can be. These information and methods can be used to optimize the result according to their requirement. © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications [IConAMMA 2017]. Keywords: Metal Matrix composite, Grey relational analysis, Response surface methodology, dielectric, ANOVA.
1.
Introduction
Electrical discharge machining process is a non- conventional machining process, and can process hard materials. Machining force exerted is very low in comparison to the mechanical machining process[1]. It is a highly developed and demanded technology which accounts 7% sales of all machine tool in the world [2]. This process machine electrically conductive materials using precise and control sparks occurs between workpiece and electrode which are submerged into a dielectric fluid [3]. Two Russian engineers, B. R. Lazarenko and N. I. lazarenko, were developed EDM in 1943. They controlled the gap distance between workpiece and electrode by using dielectric and applied a series of voltage pulses which generated a series of discrete electrical spark. There are millions of spark generated in a second which generate high temperature instantaneously and remove material from workpiece and also create wear on electrode. This is a technique of non-contact machining [4,5]. Corresponding Author Tel : +918804442868 E-mail address: [email protected]
2214-7853 © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications [IConAMMA 2017].
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Nomenclature MMC
Metal Matrix Composite
GRA
Grey Relational Analysis
ANOVA
Analysis of Variance
RSM
Response Surface Methodology
MRR
Material Removal Rate
SiC
Silicon carbide.
PMEDM
Powder Mixed Electric Discharge Machining
Nowadays, Metal matrix composite in trend and significantly increased, there are many ceramics materials which are extensively used to re-inforce metal composites. MMCs materials have superior properties such as high compressive strength, high refractoriness, high hardness, wear resistance, etc. which makes them suitable to use reinforcement in matrices [6]. MMC have properties such as low density, chemical inertness, corrosion resistance and high specific strength [7]. These advantage of MMC makes it suitable for use in aerospace, defense, sports, turbine engine blades, automotive, electronics industries and recreation [8]. When SiC particles used in MMC its machining properties decreases because of increase in hardness and brittleness [9]. It can be used to make turbine engine blades, skin and truss of airplanes, the inertial navigation platform and support components of satellites, electronic packaging and so on [10]. There are many investigation has been done on metals and alloy materials. Researcher moved from oil to PMEDM and the result is very good. 2. Working Principle The working principle of EDM process is based on the erosion of workpiece material by melting and vaporizing. This erosion of material occurs by supplying electrical energy between a workpiece and a tool (electrode) submerged into a dielectric and separated by a small gap called spark gap. Discharge occurs in this gap creating sparks. This sparks erode the workpiece material and hence machining performance. Erosion takes place in workpiece by melting and vaporizing. A dielectric fluid may de-ionized water or powder mixed de-ionized water or hydrocarbon oil or gas etc. The schematic diagram given in figure 1 shows the working principle of Die-Sink EDM.
Figure 1: Schematic Diagram of Die-Sink EDM process
3.
Reinforced Materials Each and every material has their own properties. Sometimes, it is needed to improve due to requirement. When some other material used as a secondary material to improve the properties of parent material then this type of material is known as reinforced material. Nowadays composite materials and hybrid composite material are in trend. These MMC materials are fabricated by using different reinforced material according to requirement. Some of reinforced materials are mentioned below:
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3.1 Carbides Carbide compounds are composed of carbon and element. There are many carbide compounds available and some of them are used in MMCs fabrication like SiC, B4C and TiC. Carbide compounds have high hot hardness and excellent wear resistance. 3.1.1 SiC This compound is a composition of silicon and carbon and also known as carborundum. This compound used for the requirement of high endurance like car clutches and brakes, bulletproof vests etc. and also used as abrasive particles. Addition of SiC into MMCs material improve hardness, tensile strength and damping capacity [11,12]. 3.1.2 B4C Boron carbide also known as one of the hardest material. It has good chemical resistance, good nuclear properties and low density. Due to high hardness and wear resistance it is used for polishing and fabrication of nozzles for slurry pumping. Addition of B4C into MMCs improve mechanical and tribological property [13]. 3.1.3 TiC It is also an extremely hard material and has appearance of black powder. It has high abrasive resistance and used as surface coating on metal parts. MMCs fabricated by using TiC have yield strength up to 1100 Mpa and elongation to fracture increases by 6% [14]. 3.2 Oxides An oxide compound consist oxygen and element. It ranges from solid to gas like H2O, N2O, SiO2, MgO, Al2O3, Fe3O4 and CaO. Sometimes oxide damage metals and sometimes protect like rusting of iron and oxide formation in aluminum metal. 3.2.1 Al2O3 Aluminum oxide is a composition of aluminum and oxygen. It is electrically insulator but has relatively high thermal conductivity and insoluble in water. It is used to produce aluminum metal and also as a abrasive particles due to its hardness. Adding aluminium oxide to the MMCs material improves tensile and yield strength as well as wear resistance [15,16]. 3.2.2 MgO Magnesium oxide is a white hygroscopic solid refractory material. It has high thermal conductivity and low electrical conductivity. It is used as wallboard fabrication which has several characteristics like fire resistance, moisture resistance and strength. Adding MgO as reinforced material improves hardness and compressive strength of the material [17]. 3.3 Nitrides It is a compound of nitrogen and works as refractory material. It is used as hard coating and cutting material. There are some nitrides like ALN and Si3N4 which are commercially used. 3.3.1 AlN (Aluminum nitride) It is a nitride of aluminium. It has piezoelectric properties and also a good resistance of molten salt including chloride. It is widely used in opto electronic and military applications. AlN reinforced particles improves the tensile strength and also enhance the microstructure of MMCs material [18]. 3.3.2 Si3N4 (Silicon Nitride) It is a compound of silicon element and nitrides. It is a high melting point solid and white in clour. It is used in automobile industries, bearing, medical, metal works and cutting tools. Adding Si3N4 into MMCs material has comparable tensile but ductility and yield strength are much higher than SiC/Al [19].
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Dielectric Dielectric initially works as an insulator. When electric field applied between workpiece and electrode thorough dielectric medium it get polarized and breakdown occurs at breakdown voltage[20]. It may be in gaseous (argon and helium) or liquid (hydrocarbon oil, deionized water and PMEDM) form. Researchers have performed many experiments and noticed that different dielectric has different effect on machining response. Eckart Uhlmann et al. [21] stated that erosion varies with dielectric. Gaseous dielectric has higher erosion whereas hydrocarbon oil dielectric has least. F.Q. Hu et al. [9] and sarabjeet singh sidhu et al. [22] confirmed in his experiment that PMEDM improves the machining quality and gives better result than convention EDM. There are two images depicted (in figure 2) which shows the morphological difference between conventional and PMEDM.
Figure 2 Left: PMEDM surface pf material: a) without additives, b) with Gr additives; right: SEM micrograpgh of recast layer: a) coarse sparked (without addtives), b) fine sparked (with Gr additives)[22].
Mixing powder into dielectric is not only the way to improve the quality of the responses but varying dielectric can also improves the responses. Chen el al.[23] proved that it can be by his research which is shown in figure 3 & 4.
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Figure 3 SEM images of the crack distribution on machined surface for different dielectrics[23].
5.
Figure 4 Cross-section of the microstructure near the top of machined surface for different dielectric.
Methods In Die sink EDM, There are various methods used to design experiments, analyze responses and optimize process parameters. There are some methods:
5.1 Response Surface Methodology (RSM) RSM (Box and Draper, 1987) is a group of mathematical and statistical techniques for empirical model. In this methodology center composite design and Box-Behnken are two major designing techniques. In RSM, results are obtained by iterative process which minimizes the error. It optimizes the responses obtained from a number of independent input variables. The errors present in RSM are of random type, measurement error due to inaccuracy and noise error due to incomplete iterative process [24]. Characteristics of Response Surface Methodology[24]. Step 1: Selection of independent variable. Step 2: Selection of experiment Design. Step 3: Treatment of experimental data by mathematically and statistically. Step 4: Model fitness evaluation. Step 5: Verification and checking possible displacement towards optimal region. Step 6: Optimizing the response data.
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The sequential nature of RSM is depicted in figure 5[25].
Figure 5 Sequential nature of RSM.
5.2 Relation Grey Analysis (GRA) There are multiple input parameters as well as responses. Each response has a particular combination of input parameters. Therefor different responses have optimal value at different combination of input parameters. GRA method used to get a particular combination of input parameters where all the responses are optimal or about to optimal. It is an effective technique to investigate correlation among multiple sequence[26]. When model of any system is unsure or the information is incomplete then grey theory can used to get a solution[27]. Characteristics of Relation Grey Analysis. Identify the process parameters and performance characteristics to be evaluated. Determine the number of process parameters and their levels. Design the experiment with appropriate orthogonal array and performed experiment. Normalized the responses results between 0 and 1. Apply GRA technique and calculate grey relational coefficient (GRC). Determine the grey relational grade (GRD) by averaging GRC. Analyze the responses using GRD and ANOVA. Select the optimal levels of corresponding optimal value. Perform confirmation test and verify optimal process parameters.
All the response sequences are normalized in the form of Higher the better (HTB) or Lower the better (LTB). Normalization equation for HTB[28]: y
… … … 5.1
Normalization equation for LTB: y
… … … 5.2
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Where, xi(k) = Observed value and yi(k) = normalized response. For the ith run of the kth response. Normalized sequence used in grey relational analysis to determine grey relational coefficient (GRC). The grey relational coefficient ( ) can determine as: ξ
∆ ∆
∆
… … … 5.3
∆
Where, ∆max = global maximum and ∆min = global minimum. Of normalized value of kth response. is a distinguishing factor lies between 0 and 1 and its purpose is to compress or expand the GRC range. After the determination of GRC the average value of GRC, it taken as the grey relational grade (GRG) δi , is calculated as: δ
1
ξ
… … … 5.4
Where, n = no. of process responses. 6.
Role of reinforcement and machining operation on MMC material
Metal matrix composites materials are made of different composition of continuous metal matrix and one or more discontinuous reinforce phases. The reinforce materials are present in whiskers, fibers or particles phase [29]. MMCs materials are fabricated by either casting method or powder metallurgy technique (P/M) [30]. Properties of MMCs material depends on reinforce materials and its phases. There are some reinforce materials which are used in MMCs fabrication like carbides (SiC, B4C, TiC), oxides (Al2O3, Mgo, SiO), nitrides (ALN and Si3N4 etc. [31, 32]. Many materials investigated with different dielectric and powder mixed dielectric there after MMC comes in demand as its properties suitable to replace metals and alloys at some place.
Figure 6 Left: mechanically alloyed intermetallic; right: atomized inter-metallic reinforcing a 2014 aluminum ll
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Figure 8 White layer formation after EDM: (a) at any level. (b) at optimum level.
Figure 7 Cracks on surface aftre EDM: (a) at any level. (b) at optimum level.
Now researcher start investigating the MMC materials and tried to improve quality of machined surface, minimization of recast layer formation and optimize many more responses. Song et al. [9] Performs an experiment on Al-MMC and find the effect on surface of the composite in conventional EDM and PMEDM. The result shows that PMEDM gives better result than convention EDM. It improves the surface finish, wear resistance, hardness and also improves the corrosion resistance of the surface. To measure the all outputs some techniques and instrument are used which are as follows scanning electron microscope, wear taster and surface micro topography simultaneously Kumar et al. [33] states that surface integrity of Al-MMC is increased in cryogenic EDM than conventional EDM. It also reduces the electrode wear, decreases electrode temperature and workpiece temperature where recast layer increases with discharge current and pulse on time. Pai et al. [29] used Al–MMC a cast metal matrix composites as a workpice and performed the experiment with varying the parameters and found that higher MRR can be obtain with larger current and pulse on time. They also find that there are some problem of radial overcut and tapercity and at higher current dimension accuracy also get affected. SEM analysis was used to study the surface characteristics of the machined surface. Rajesh et al. [34] have taken Al-SiC 24% MMC and used multi objective optimization techniques and determine the optimal machining condition. To design the experiment Box-Behnken Central composite method is used, ANOVA used to check the significant parameters, TOPSIS methodology used to determine single numerical index and RSM used to develop second order mathematical equation. All these methods used to determine the closeness machining coefficient.There are some figures(6,7 and 8) in which the morphology of experimental result shows difference between experiment performed an any level and at optimum level[35].
Figure 9 Morphology of debris particles produced in EDM: (a) at any level. (b) at optimum level.
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Kumaraswamidhas et al. [18] used Aluminium 2618 matrix material with different reinforce particles( shown in figure 9) such as Zirconium Boride (Zrb2), Aluminium Nitride (ALN) and Silicon Nitride (Si3N4) with varying wt% (0,2,4,6,8). Optimized parameters for the responses determine by using genetic algorithm, percentage of contribution calculated by using ANOVA. Satyanarayana et al. [36] performed a no. of experiment using rotary tube of brass material to machine Al metal matrix composites. The percentage of SiC and the speed of rotary tube varies with the parameters. From the experiment it is noticed that maximum MRR obtained in rotating tube than rotating solid electrode, increasing percentage of SiC decreases the MRR as well as TWR increases. When rotation speed increased with injection flushing it gives a better response. Kumaran et al. [37] used Al 4032 MMC reinforced with Zrb2 and Zrb2 in various wt%(0,2,4,6,8,). From the experiment and property testing it is found that increasing reinforcement particles enhances the strength and hardness property where MRR, depth of cut and TWR are minimum. From all the above it is found that Al MMC has a wide application in various industries. Mixing with different reinforced particle properties or Al alloy increases and suits the application. In Fig 6, two different morphology of an reinforced AL-MMC can be seen[38] As all the researchers concentrated on the powder particles like SiC, Zrb2, Si3N4, ALN etc. Amitesh et al.[39] and Bhaskar et al. [3] reviewed many papers based on Al MMC and got a conclusion that Al MMC are the one of important type of composite due to its light weight, low density and high strength. They also reviewed various methods which is used to optimize the machining process meters and the desire responses like genetic algorithm, neutral network and gray relation analysis etc. The EDM processes also combines with different machining processes like AJM, ECM, surface grinding etc. to get the advantage of hybrid machining. The mechanical and machining properties of Al MMC with varying concentration. Al MMC can also be machined by using PMEDM where powder particles may SiO2, Al2O3 etc. as they have low current intensity which probably improves the TWR, surface roughness and can minimize recast layer formation. 7.
Result and discussion
There are a number of grades (MMC) of a single parent material available due to presence variety of reinforcement, as percentage and type of enforcement changes the desired properties such as wear resistance[40], damping capacity[12], tensile and yield strength[41], conductivity and corrosive resistance[22], porosity level[42] and surface hardness[43] obtained. Therefore, it has a wide range of use. From the literature review it is noticed that nowadays AL MMC is in trend and lots of research have been performed with varying reinforce material and their concentration also they have tried different optimizing techniques. They can also vary the dielectric instead of using powder mixed dielectric to improve MRR and surface roughness. EDM performed an important role in machining MMC material as some of MMC materials are very difficult to machine. PMEDM also improves MMR, surface roughness and minimized the white layer thickness while using same dielectric and at same parameter. Using Distilled water increases MRR in some case and surface instead of using hydrocarbon oil. Various methods such as RSM, ANOVA, GRA, TOPSIS, Fuzzy logic etc. are available for performing different analyzing and optimizing processes[44–47]. Some of the responses may be improved by using steam. As steam has high specific heat it can perform an effective role in recast layer thickness minimization and improving surface roughness. Reference [1]
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ScienceDirect Materials Today: Proceedings 5 (2018) 24428–24438
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IConAMMA_2017
A Review Paper on Machining of Metal Matrix Composite and Optimizing Methods used in Electrical Discharge Machining Kamlesh Paswana*, Somnath Chattopadhyayab, Alokesh Pramanikc a b
Research Scholar, Department of mechanical engineering, Indian institute of Technology (Indian School of Mines) Dhanbad
Associate professor, Department of mechanical engineering, Indian institute of Technology (Indian School of Mines) Dhanbad c
Lecturer, Department of mechanical engineering, Curtin, University, Australia
Abstract
Electric discharge machining is a non-conventional thermal erosion process. In this article investigation has been done on the effect of different reinforcement (carbides, oxides and nitrides), dielectric (kerosene, distilled water and PMEDM) and methods (RSM and GRA) for machining of MMC materials and optimizing the responses. Variation in responses due to all these factors are properly examined and depicted in figures. Result shows that there are various reinforced materials available and different methods have been developed effectively and many more can be. These information and methods can be used to optimize the result according to their requirement. © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications [IConAMMA 2017]. Keywords: Metal Matrix composite, Grey relational analysis, Response surface methodology, dielectric, ANOVA.
1.
Introduction
Electrical discharge machining process is a non- conventional machining process, and can process hard materials. Machining force exerted is very low in comparison to the mechanical machining process[1]. It is a highly developed and demanded technology which accounts 7% sales of all machine tool in the world [2]. This process machine electrically conductive materials using precise and control sparks occurs between workpiece and electrode which are submerged into a dielectric fluid [3]. Two Russian engineers, B. R. Lazarenko and N. I. lazarenko, were developed EDM in 1943. They controlled the gap distance between workpiece and electrode by using dielectric and applied a series of voltage pulses which generated a series of discrete electrical spark. There are millions of spark generated in a second which generate high temperature instantaneously and remove material from workpiece and also create wear on electrode. This is a technique of non-contact machining [4,5]. Corresponding Author Tel : +918804442868 E-mail address: [email protected]
2214-7853 © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications [IConAMMA 2017].
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Nomenclature MMC
Metal Matrix Composite
GRA
Grey Relational Analysis
ANOVA
Analysis of Variance
RSM
Response Surface Methodology
MRR
Material Removal Rate
SiC
Silicon carbide.
PMEDM
Powder Mixed Electric Discharge Machining
Nowadays, Metal matrix composite in trend and significantly increased, there are many ceramics materials which are extensively used to re-inforce metal composites. MMCs materials have superior properties such as high compressive strength, high refractoriness, high hardness, wear resistance, etc. which makes them suitable to use reinforcement in matrices [6]. MMC have properties such as low density, chemical inertness, corrosion resistance and high specific strength [7]. These advantage of MMC makes it suitable for use in aerospace, defense, sports, turbine engine blades, automotive, electronics industries and recreation [8]. When SiC particles used in MMC its machining properties decreases because of increase in hardness and brittleness [9]. It can be used to make turbine engine blades, skin and truss of airplanes, the inertial navigation platform and support components of satellites, electronic packaging and so on [10]. There are many investigation has been done on metals and alloy materials. Researcher moved from oil to PMEDM and the result is very good. 2. Working Principle The working principle of EDM process is based on the erosion of workpiece material by melting and vaporizing. This erosion of material occurs by supplying electrical energy between a workpiece and a tool (electrode) submerged into a dielectric and separated by a small gap called spark gap. Discharge occurs in this gap creating sparks. This sparks erode the workpiece material and hence machining performance. Erosion takes place in workpiece by melting and vaporizing. A dielectric fluid may de-ionized water or powder mixed de-ionized water or hydrocarbon oil or gas etc. The schematic diagram given in figure 1 shows the working principle of Die-Sink EDM.
Figure 1: Schematic Diagram of Die-Sink EDM process
3.
Reinforced Materials Each and every material has their own properties. Sometimes, it is needed to improve due to requirement. When some other material used as a secondary material to improve the properties of parent material then this type of material is known as reinforced material. Nowadays composite materials and hybrid composite material are in trend. These MMC materials are fabricated by using different reinforced material according to requirement. Some of reinforced materials are mentioned below:
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3.1 Carbides Carbide compounds are composed of carbon and element. There are many carbide compounds available and some of them are used in MMCs fabrication like SiC, B4C and TiC. Carbide compounds have high hot hardness and excellent wear resistance. 3.1.1 SiC This compound is a composition of silicon and carbon and also known as carborundum. This compound used for the requirement of high endurance like car clutches and brakes, bulletproof vests etc. and also used as abrasive particles. Addition of SiC into MMCs material improve hardness, tensile strength and damping capacity [11,12]. 3.1.2 B4C Boron carbide also known as one of the hardest material. It has good chemical resistance, good nuclear properties and low density. Due to high hardness and wear resistance it is used for polishing and fabrication of nozzles for slurry pumping. Addition of B4C into MMCs improve mechanical and tribological property [13]. 3.1.3 TiC It is also an extremely hard material and has appearance of black powder. It has high abrasive resistance and used as surface coating on metal parts. MMCs fabricated by using TiC have yield strength up to 1100 Mpa and elongation to fracture increases by 6% [14]. 3.2 Oxides An oxide compound consist oxygen and element. It ranges from solid to gas like H2O, N2O, SiO2, MgO, Al2O3, Fe3O4 and CaO. Sometimes oxide damage metals and sometimes protect like rusting of iron and oxide formation in aluminum metal. 3.2.1 Al2O3 Aluminum oxide is a composition of aluminum and oxygen. It is electrically insulator but has relatively high thermal conductivity and insoluble in water. It is used to produce aluminum metal and also as a abrasive particles due to its hardness. Adding aluminium oxide to the MMCs material improves tensile and yield strength as well as wear resistance [15,16]. 3.2.2 MgO Magnesium oxide is a white hygroscopic solid refractory material. It has high thermal conductivity and low electrical conductivity. It is used as wallboard fabrication which has several characteristics like fire resistance, moisture resistance and strength. Adding MgO as reinforced material improves hardness and compressive strength of the material [17]. 3.3 Nitrides It is a compound of nitrogen and works as refractory material. It is used as hard coating and cutting material. There are some nitrides like ALN and Si3N4 which are commercially used. 3.3.1 AlN (Aluminum nitride) It is a nitride of aluminium. It has piezoelectric properties and also a good resistance of molten salt including chloride. It is widely used in opto electronic and military applications. AlN reinforced particles improves the tensile strength and also enhance the microstructure of MMCs material [18]. 3.3.2 Si3N4 (Silicon Nitride) It is a compound of silicon element and nitrides. It is a high melting point solid and white in clour. It is used in automobile industries, bearing, medical, metal works and cutting tools. Adding Si3N4 into MMCs material has comparable tensile but ductility and yield strength are much higher than SiC/Al [19].
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Dielectric Dielectric initially works as an insulator. When electric field applied between workpiece and electrode thorough dielectric medium it get polarized and breakdown occurs at breakdown voltage[20]. It may be in gaseous (argon and helium) or liquid (hydrocarbon oil, deionized water and PMEDM) form. Researchers have performed many experiments and noticed that different dielectric has different effect on machining response. Eckart Uhlmann et al. [21] stated that erosion varies with dielectric. Gaseous dielectric has higher erosion whereas hydrocarbon oil dielectric has least. F.Q. Hu et al. [9] and sarabjeet singh sidhu et al. [22] confirmed in his experiment that PMEDM improves the machining quality and gives better result than convention EDM. There are two images depicted (in figure 2) which shows the morphological difference between conventional and PMEDM.
Figure 2 Left: PMEDM surface pf material: a) without additives, b) with Gr additives; right: SEM micrograpgh of recast layer: a) coarse sparked (without addtives), b) fine sparked (with Gr additives)[22].
Mixing powder into dielectric is not only the way to improve the quality of the responses but varying dielectric can also improves the responses. Chen el al.[23] proved that it can be by his research which is shown in figure 3 & 4.
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Figure 3 SEM images of the crack distribution on machined surface for different dielectrics[23].
5.
Figure 4 Cross-section of the microstructure near the top of machined surface for different dielectric.
Methods In Die sink EDM, There are various methods used to design experiments, analyze responses and optimize process parameters. There are some methods:
5.1 Response Surface Methodology (RSM) RSM (Box and Draper, 1987) is a group of mathematical and statistical techniques for empirical model. In this methodology center composite design and Box-Behnken are two major designing techniques. In RSM, results are obtained by iterative process which minimizes the error. It optimizes the responses obtained from a number of independent input variables. The errors present in RSM are of random type, measurement error due to inaccuracy and noise error due to incomplete iterative process [24]. Characteristics of Response Surface Methodology[24]. Step 1: Selection of independent variable. Step 2: Selection of experiment Design. Step 3: Treatment of experimental data by mathematically and statistically. Step 4: Model fitness evaluation. Step 5: Verification and checking possible displacement towards optimal region. Step 6: Optimizing the response data.
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The sequential nature of RSM is depicted in figure 5[25].
Figure 5 Sequential nature of RSM.
5.2 Relation Grey Analysis (GRA) There are multiple input parameters as well as responses. Each response has a particular combination of input parameters. Therefor different responses have optimal value at different combination of input parameters. GRA method used to get a particular combination of input parameters where all the responses are optimal or about to optimal. It is an effective technique to investigate correlation among multiple sequence[26]. When model of any system is unsure or the information is incomplete then grey theory can used to get a solution[27]. Characteristics of Relation Grey Analysis. Identify the process parameters and performance characteristics to be evaluated. Determine the number of process parameters and their levels. Design the experiment with appropriate orthogonal array and performed experiment. Normalized the responses results between 0 and 1. Apply GRA technique and calculate grey relational coefficient (GRC). Determine the grey relational grade (GRD) by averaging GRC. Analyze the responses using GRD and ANOVA. Select the optimal levels of corresponding optimal value. Perform confirmation test and verify optimal process parameters.
All the response sequences are normalized in the form of Higher the better (HTB) or Lower the better (LTB). Normalization equation for HTB[28]: y
… … … 5.1
Normalization equation for LTB: y
… … … 5.2
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Where, xi(k) = Observed value and yi(k) = normalized response. For the ith run of the kth response. Normalized sequence used in grey relational analysis to determine grey relational coefficient (GRC). The grey relational coefficient ( ) can determine as: ξ
∆ ∆
∆
… … … 5.3
∆
Where, ∆max = global maximum and ∆min = global minimum. Of normalized value of kth response. is a distinguishing factor lies between 0 and 1 and its purpose is to compress or expand the GRC range. After the determination of GRC the average value of GRC, it taken as the grey relational grade (GRG) δi , is calculated as: δ
1
ξ
… … … 5.4
Where, n = no. of process responses. 6.
Role of reinforcement and machining operation on MMC material
Metal matrix composites materials are made of different composition of continuous metal matrix and one or more discontinuous reinforce phases. The reinforce materials are present in whiskers, fibers or particles phase [29]. MMCs materials are fabricated by either casting method or powder metallurgy technique (P/M) [30]. Properties of MMCs material depends on reinforce materials and its phases. There are some reinforce materials which are used in MMCs fabrication like carbides (SiC, B4C, TiC), oxides (Al2O3, Mgo, SiO), nitrides (ALN and Si3N4 etc. [31, 32]. Many materials investigated with different dielectric and powder mixed dielectric there after MMC comes in demand as its properties suitable to replace metals and alloys at some place.
Figure 6 Left: mechanically alloyed intermetallic; right: atomized inter-metallic reinforcing a 2014 aluminum ll
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Figure 8 White layer formation after EDM: (a) at any level. (b) at optimum level.
Figure 7 Cracks on surface aftre EDM: (a) at any level. (b) at optimum level.
Now researcher start investigating the MMC materials and tried to improve quality of machined surface, minimization of recast layer formation and optimize many more responses. Song et al. [9] Performs an experiment on Al-MMC and find the effect on surface of the composite in conventional EDM and PMEDM. The result shows that PMEDM gives better result than convention EDM. It improves the surface finish, wear resistance, hardness and also improves the corrosion resistance of the surface. To measure the all outputs some techniques and instrument are used which are as follows scanning electron microscope, wear taster and surface micro topography simultaneously Kumar et al. [33] states that surface integrity of Al-MMC is increased in cryogenic EDM than conventional EDM. It also reduces the electrode wear, decreases electrode temperature and workpiece temperature where recast layer increases with discharge current and pulse on time. Pai et al. [29] used Al–MMC a cast metal matrix composites as a workpice and performed the experiment with varying the parameters and found that higher MRR can be obtain with larger current and pulse on time. They also find that there are some problem of radial overcut and tapercity and at higher current dimension accuracy also get affected. SEM analysis was used to study the surface characteristics of the machined surface. Rajesh et al. [34] have taken Al-SiC 24% MMC and used multi objective optimization techniques and determine the optimal machining condition. To design the experiment Box-Behnken Central composite method is used, ANOVA used to check the significant parameters, TOPSIS methodology used to determine single numerical index and RSM used to develop second order mathematical equation. All these methods used to determine the closeness machining coefficient.There are some figures(6,7 and 8) in which the morphology of experimental result shows difference between experiment performed an any level and at optimum level[35].
Figure 9 Morphology of debris particles produced in EDM: (a) at any level. (b) at optimum level.
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Kumaraswamidhas et al. [18] used Aluminium 2618 matrix material with different reinforce particles( shown in figure 9) such as Zirconium Boride (Zrb2), Aluminium Nitride (ALN) and Silicon Nitride (Si3N4) with varying wt% (0,2,4,6,8). Optimized parameters for the responses determine by using genetic algorithm, percentage of contribution calculated by using ANOVA. Satyanarayana et al. [36] performed a no. of experiment using rotary tube of brass material to machine Al metal matrix composites. The percentage of SiC and the speed of rotary tube varies with the parameters. From the experiment it is noticed that maximum MRR obtained in rotating tube than rotating solid electrode, increasing percentage of SiC decreases the MRR as well as TWR increases. When rotation speed increased with injection flushing it gives a better response. Kumaran et al. [37] used Al 4032 MMC reinforced with Zrb2 and Zrb2 in various wt%(0,2,4,6,8,). From the experiment and property testing it is found that increasing reinforcement particles enhances the strength and hardness property where MRR, depth of cut and TWR are minimum. From all the above it is found that Al MMC has a wide application in various industries. Mixing with different reinforced particle properties or Al alloy increases and suits the application. In Fig 6, two different morphology of an reinforced AL-MMC can be seen[38] As all the researchers concentrated on the powder particles like SiC, Zrb2, Si3N4, ALN etc. Amitesh et al.[39] and Bhaskar et al. [3] reviewed many papers based on Al MMC and got a conclusion that Al MMC are the one of important type of composite due to its light weight, low density and high strength. They also reviewed various methods which is used to optimize the machining process meters and the desire responses like genetic algorithm, neutral network and gray relation analysis etc. The EDM processes also combines with different machining processes like AJM, ECM, surface grinding etc. to get the advantage of hybrid machining. The mechanical and machining properties of Al MMC with varying concentration. Al MMC can also be machined by using PMEDM where powder particles may SiO2, Al2O3 etc. as they have low current intensity which probably improves the TWR, surface roughness and can minimize recast layer formation. 7.
Result and discussion
There are a number of grades (MMC) of a single parent material available due to presence variety of reinforcement, as percentage and type of enforcement changes the desired properties such as wear resistance[40], damping capacity[12], tensile and yield strength[41], conductivity and corrosive resistance[22], porosity level[42] and surface hardness[43] obtained. Therefore, it has a wide range of use. From the literature review it is noticed that nowadays AL MMC is in trend and lots of research have been performed with varying reinforce material and their concentration also they have tried different optimizing techniques. They can also vary the dielectric instead of using powder mixed dielectric to improve MRR and surface roughness. EDM performed an important role in machining MMC material as some of MMC materials are very difficult to machine. PMEDM also improves MMR, surface roughness and minimized the white layer thickness while using same dielectric and at same parameter. Using Distilled water increases MRR in some case and surface instead of using hydrocarbon oil. Various methods such as RSM, ANOVA, GRA, TOPSIS, Fuzzy logic etc. are available for performing different analyzing and optimizing processes[44–47]. Some of the responses may be improved by using steam. As steam has high specific heat it can perform an effective role in recast layer thickness minimization and improving surface roughness. Reference [1]
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