Articles
  • Modeling and optimization of material removal rate and surface roughness for Al6010 HMMCs on WEDM using Response Surface Methodology

  • Mukesh Kumara, S.K. Tamanga,*, Dipika Devib, M. Dabia, K. K. Prasada,c and R. Thirumalaid

  • aDepartment of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh-791109, India
    bDepartment of Civil Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh-791109, India
    cCentre for Sensor, Instrumentation and Cyber Physical System Engineering (SeNSE), Indian Institute of Technology Delhi, New Delhi-110016, India
    dDepartment of Mechanical Engineering, Dr. N.G.P Institute of Technology, Coimbatore - 641 048, India

  • This article is an open access article distributed under the terms of the Creative Commons Attribution Non-Commercial License (http://creativecommons.org/licenses/by-nc/4.0) which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

A Hybrid metal matrix composite (HMMCs) material has gained a lot of interest among industries due to its superior properties. Some of these properties are light in weight, high strength & rigidity, and high-temperature resistance. However, due to poor machinability, faster tool wear, machining of such materials exhibits greater challenges. The WEDM of aluminum-based HMMC Al6010 (10% SiC and 15% Al2O3) is investigated. The input variable viz., pulse on time (Ton), pulse of time (Toff), peak current (I) and servo voltage (V) of the WEDM process was modelled using Response Surface Methodology (RSM). The investigation was carried out through varying their effect on the material removal rate (MRR) and surface roughness (Ra). Using desirability analysis an attempt has been made to optimize the multiple responses simultaneously, the MRR and Ra were optimized for desirability and optimum result found as Ra = 1.58 µm and MRR = 18.31 mm3/min corresponding to V = 33.32 volt, Ton = 117.45 µs, Toff = 45.041 µs and I = 219.70 A. In addition, the analysis of variance (ANOVA) is performed to determine the significance of the selected input variable. It has been found that as peak current increases, MRR increases and Ra decreases. The RSM model's validity and appropriateness are confirmed by the test results.


Keywords: Hybrid metal matrix composite, WEDM, RSM, Surface quality, ANOVA

This Article

  • 2022; 23(3): 373-382

    Published on Jun 30, 2022

  • 10.36410/jcpr.2022.23.3.373
  • Received on Feb 1, 2022
  • Revised on Mar 7, 2022
  • Accepted on Mar 15, 2022

Correspondence to

  • S.K. Tamang

  • Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh-791109, India
    Tel : +919402953139 Fax: +91 (0)360 2257872

  • E-mail: sktnerist@gmail.com