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An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Kannan P. R., Periasamy K., Pravin P., Vinod Kumaar J. R.

Materials Science Poland

2022

Vol. 40, No. 3

12--26

In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement. The machining experiments were conducted by varying the input parameters such as voltage (Vs), wire feed rate (Fw), current (Ip), pulse on time (ONT) and pulse off time (OFFT), on wire breakage. The effect of voltage level and wire breakage frequency was analysed. The parameter combinations for machining the slot of size 5 mm width and 10 mm height with high machining rate (MR) and less surface roughness (Ra) were analysed using the Criteria Importance Through Intercriteria Correlation (CRITIC) and simple additive weighting (SAW) methods. The wire breakage frequency is lesser at minimum peak current. The optimal parameter combination for higher MR and lower Ra is found to be at 30 V, 7 mm/min, 30 A, 120 μs (ONT) and 70 μs (OFFT). Analysis of variance (ANOVA) is performed to understand the significant factors affecting the WEDM process. ANOVA results predict that wire feed rate and voltage contribute 47.82% and 21.23%, respectively, to MR; and pulse on time shows a 23.06% influence on surface roughness. Scanning electron microscopy (SEM) was used to ascertain the pattern of wire breakage in WEDM, and based on the results obtained from employing this technique, it is inferred that the erosion and breakage of the wire are not instantaneous and that a cone shape is formed on the either portion of the wire.

Nonlinear hydromagnetic flow, heat and mass transfer over an accelerating vertical surface in the presence of internal heat generation and chemical reaction

Kandasamy R., Periasamy K.

International Journal of Applied Mechanics and Engineering

2005

Vol. 10, no 2

245-252

An analysis is carried out to study a nonlinear hydromagnetic flow, heat and mass transfer over an accelerating vertical surface with internal heat generation and chemical reaction. The fluid is assumed to be incompressible, viscous, electrically conducting and Boussinesq. A magnetic field is applied transversely to the direction of the flow. The similarity transformation has been utilized to convert the governing partial differential equations into ordinary differential equations and then the numerical solution of the problem is drawn using Runge Kutta Gill method. Numerical calculations for different values of dimensionless parameters entering the problem under consideration are carried out for the purpose of illustrating the results graphically. Examinations of such flow models reveal the influence of the chemical reaction, Prandtl number and strength of the magnetic field.