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2 2021

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Optimization of Output Responses during EDM of AZ91 Magnesium Alloy using Grey Relational Analysis and TOPSIS

Tajdeen A., Megalingam A.

Archives of Metallurgy and Materials

2021

Vol. 66, iss. 4

1105--1113

Unconventional machining of magnesium alloys through die sinking and Wire Electrical Discharge Machining (WEDM) processes are preferred over conventional machining processes to overcome the rapid loss in strength and affinity that occurs with tool materials at high temperatures. in the present study, AZ91 magnesium alloy is machined in EDM using a prepared alloy tool (copper alloyed with titanium diboride). Based on Taguchi’s L27 orthogonal array, a total of 27 experiments have been conducted by varying the process parameters such as pulse on time (Ton), gap voltage (Vg) and current (Ip) with three different levels. Techniques for Order Preference by Similarity to Ideal Solution (TOPSIS) and Grey Relational Analysis (GRA) have been applied to optimize the response parameters of EDM to obtain maximum Material Removal Rate (MRR) and minimum Tool Wear Rate (TWR) and Surface Roughness (SR). Analysis of variance (ANOVA) is carried out based on F-test at a confidence interval of 95% to confirm the significant influence of individual parameters. From the above two optimization techniques, the obtained optimal values are current 15 A, gap voltage 55 V, pulse on time 30 μs and an error of less than 5% is observed from the confirmation experiments. Scanning Electron Microscope (SEM) images revealed that there is no formation of cracks but micro pits and holes are observed.

Dry Sliding Friction and Wear Behaviour of Leaded Tin bronze for Bearing and Bushing Application

Dinesh D., Megalingam A.

Archives of Metallurgy and Materials

2021

Vol. 66, iss. 4

1095--1104

Among different bearing materials, copper-based alloys are the most important source for bearing and bushing applications. In this work, the tribological behavior of a leaded tin bronze (Cu-22Pb-4Sn) against an EN31 Steel for various loads (20 N, 70 N, 120 N) and different sliding velocity (1 m/s, 3 m/s, 5 m/s) at 3000 m sliding distance is performed using a pin on disk tribometer. Irrespective of all loads and sliding velocity, a higher specific wear rate is observed at 1 m/s and 120 n that fails to facilitate the formation of lubricating film, whereas a lower specific wear rate is evident when the sliding velocity is increased to 5 m/s. This is attributed to the formation of a stable oxide layer that has been confirmed through the energy dispersive X-ray spectroscopy analysis and scanning electron microscopy. The coefficient of friction is observed in reducing trend from 0.69 to 0.48 for the increasing load (70 N, 120 N) and sliding velocity (3 m/s and 5 m/s) due to stable thin oxide film formation. Also, the increase in frictional force and loading the interacting surface temperature is increased to a maximum of 102°C. The grey relational analysis indicates that the optimal parameters for the minimum specific wear rate and coefficient of friction is 120 N and 5 m/s that has been confirmed with experimental analysis.