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WEDM parametric study of AA7075/6 wt.% Ni-COATED Al2O3(P) composite miniature GEARS

Wybrane pełne teksty z tego czasopisma
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Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Nowadays, gears are essential components in various electro-mechanical devices. Nevertheless, the fabrication of miniature-sized gears is very complicated. The present paper is focused on assessing the influence of the WEDM parameters on the material removal rate (MRR) and surface roughness (Ra) of AA7075/6 wt.% nickel-coated Al2O3 composite miniature gears. Initially, the theoretical design calculations were performed, and consequently the results were validated using ANSYS 19.0 software. Furthermore, experiments were modelled in accordance with Taguchi’s L9 orthogonal array. Optimal combinations of pulse on time, pulse off time and peak current were assessed using grey relational analysis (GRA) coupled with principal component analysis (PCA). The significance of the parametric influence on the machining responses was also evaluated using the ANOVA technique. Consequently, confirmation tests were conducted to verify the optimal parameters and the predicted results are in good agreement with the experimental findings.
Słowa kluczowe
Rocznik
Strony
89--96
Opis fizyczny
Bibliogr. 26 poz., rys., tab.
Twórcy
autor
  • Department of Mechanical Engineering, Bapatla Engineering College, Bapatla, India
  • Department of Mechanical Engineering, A.U.College of Engineering (A), Vishakhapatnam, India
autor
  • Department of Mechanical Engineering, A.U.College of Engineering (A), Vishakhapatnam, India
autor
  • Formerly Principal, SRKR Engineering College, Bhimavaram, India
Bibliografia
  • [1] Kumar S.D., Ravichandran M., Synthesis, characterization and wire electric erosion behaviour of AA7178-10 wt.% ZrB2 composite, Silicon 2018, 10(6), 2653-2662, DOI: 10.1007/s12633-018-9802-7
  • [2] Srinivasan N., Rajenthira Kumar D., Sridhar R., Niranjan G., Combined influence of size effect and temperature in micro scale deformation of 6063 aluminum gear, J. Braz. Soc. Mech. 2020), 42(6), 1-10, DOI: 10.1007/s40430-020-02414-2.
  • [3] Rai P., Barman A.G., Design optimization of spur gear using SA and RCGA, J. Braz. Soc. Mech. 2018 40(5), 1-8, DOI: 10.1007/s40430-018-1180-y.
  • [4] Jain N.K., Chaubey S.K., Review of Miniature Gear Manufacturing, Elsevier 2017, DOI: 10.1016/B978-0-12-803581-8.09159-1.
  • [5] Gupta K., Jain N.K., Laubscher R.F., Spark erosion machining of miniature gears: a critical review, Int. J. Adv. Manuf. Technol. 2015, 80(9), 1863-1877, DOI: 10.1007/s00170-015-7130-2.
  • [6] Praveen D.V., Raju D.R., Raju M.J., Optimization of machining parameters of wire-cut EDM on ceramic particles reinforced Al-metal matrix composites – A review, Mater. Today: Proc. 2020, 23, 495-498, DOI: 10.1016/j.matpr.2019.05.392.
  • [7] Chaubey S.K., Jain N.K. On productivity of WSEM proces for manufacturing meso-sized helical and bevel gears, IOP Conf. Ser.: Mater. Sci. Eng. 2018, July, 389, 1, 012007, IOP Publishing, DOI: 10.1088/1757-899X/389/1/012007.
  • [8] Alhadeff L.L., Curtis D.T., Marshall M.B., Slatter T., The application of wire electrical discharge machining (WEDM) in the prototyping of miniature brass gears, Procedia CIRP2018 77, 642-645, DOI: 10.1016/j.procir.2018.08.187.
  • [9] Chaubey S.K., Jain N.K., Investigations on surface quality of WEDM-manufactured meso bevel and helical gears, Mater. Manuf. Process 2018, 33(14), 1568-1577, DOI: 10.1080/10426914.2017.1415440.
  • [10] Ali M.Y., Mustafizul Karim A.N., Adesta E.Y.T., Ismail A.F., Idris M.N., Comparative study of conventional and micro WEDM based on machining of meso/micro sized spur gear, Int. J. Precis. Eng. 2010, 11(5), 779-784, DOI: 10.1007/s12541-010-0092-2.
  • [11] Praveen D.V., Raju D.R., Raju M.V.J., Nancharaiah T., A note on preparation of electroless nickel coating on alumina micro-particles as the forerunner to reinforce Al-MMCs, Recent Advances in Smart Manufacturing and Materials: Select Proceedings of ICEM 2020, 2021, 205, DOI: 10.1007/978-981-16-3033-0_19.
  • [12] Kumar D.S., Suman K.N.S., Kumar P.R., A study on electroless deposition of nickel on nano alumina powder under different sensitization conditions, Int. J. Adv. Manuf. Technol. 2016, 97, 59-68, DOI: 10.14257/ijast.2016.97.06.
  • [13] Praveen D.V., Raju D.R., Raju M.J., Influence of nickel coating of Al2O3 (P) reinforced AA-7075 metal matrix composites on hardness, impact strength and tensile properties, Mater. Res. Express. 2019, 6(12), 126537, DOI: 10.1088/2053-1591/ab5594.
  • [14] Chandrasekar P., Nagaraju D., Improvement of bonding strength at the interfaces in scrap Al alloy composites using electroless Ni-P coated SiC, Silicon 2022, 14(6), 2941-2952, DOI: 10.1007/s12633-021-01078-4.
  • [15] Samal P., Surekha B., Vundavilli P.R., Experimental investigations on microstructure, mechanical behavior and tribological analysis of AA5154/SiC composites by stir casting, Silicon 2022, 14(7), 3317-3328, DOI: 10.1007/s12633-021-01115-2.
  • [16] Uğur A., Nas E., Gökkaya H., Investigation of the machinability of SiC reinforced MMC materials produced by molten metal stirring and conventional casting technique in die-sinking electrical discharge machine, Int. J. Mech. Sci. 2020, 186, 105875, DOI: 10.1016/j.ijmecsci.2020.105875.
  • [17] Vijay Praveen D., Ranga Raju D., Raju J., Assessment of optimal parameters of wire EDM on Ni-coated Al22O3p/AA7075 MMCs using PCA coupled GRA, Arab J. Sci. Eng. 2021, 46(8), 7953-7966, DOI: 10.1007/s13369-021-05579-7.
  • [18] Alam M.N., Siddiquee A.N., Khan Z.A., Khan N.Z., A comprehensive review on wire EDM performance evaluation, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 2022, 236(4), 1724-1746, DOI: 10.1177/09544089221074843.
  • [19] Kumar N., Kumari S., Abhishek K., Nandi G., Ghosh N., Study on various parameters of WEDM using different optimization techniques: A review, Materials Today: Proceedings 2022, DOI: 10.1016/j.matpr.2022.04.596.
  • [20] Saha S.K., Choudhury S.K., Experimental investigation and empirical modeling of the dry electric discharge machining process, Int. J. Mach. Tools Manuf. 2009, 49(3-4), 297-308, DOI: 10.1016/j.ijmachtools.2008.10.012.
  • [21] Bellubbi S., Mallick B., Multi response optimization of ECDM process parameters for machining of micro channel in silica glass using taguchi-GRA technique, Silicon 2022, 14(8), 4249-4263, DOI: 10.1007/s12633-021-01167-4.
  • [22] Sonawane G.D., Sargade V.G., Evaluation and multi-objective optimization of nose wear, surface roughness and cutting forces using grey relation analysis (GRA), J. Braz. Soc. Mech. 2019, 41(12), 1-13, DOI: 10.1007/s40430-019-2057-4.
  • [23] Tosun N., Cogun C., Tosun G., A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method, J. Mater. Process. Technol. 2004, 152(3), 316-322, DOI: 10.1016/j.jmatprotec.2004.04.373.
  • [24] Kumar P., Meenu M., Kumar V., Optimization of proces parameters for WEDM of Inconel 825 using grey relational analysis, Decis. Sci. Lett. 2018, 7(4), 405-416.
  • [25] Gupta K., Jain N.K., Deviations in geometry of miniature gears fabricated by wire electrical discharge machining, ASME International Mechanical Engineering Congress and Exposition (Vol. 56390, p. V010T11A047). American Society of Mechanical Engineers 2013, DOI: 10.1115/IMECE2013-66560.
  • [26] Shahbazi Dastjerdi M., Mokhtarian A., Saraeian P., The effect of alumina powder in dielectric on electrical discharge machining parameters of aluminum composite A413-Al2O3 by the Taguchi method, the signal-to-noise analysis and the total normalized quality loss, Int. J. Mech. Eng. 2020, 15, 1-11, DOI: 10.1186/s40712-020-00117-z.
Uwagi
Opracowanie rekordu ze środków MEiN, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2022-2023).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-4f0642aa-7b44-444c-b355-c7f721c38557
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