FEA Modeling of Material Removal Rate in Electrical Discharge Machining of Al6063/SiC Composites

Authors: U. K. Vishwakarma , A. Dvivedi, P. Kumar

Abstract:

Metal matrix composites (MMC) are generating extensive interest in diverse fields like defense, aerospace, electronics and automotive industries. In this present investigation, material removal rate (MRR) modeling has been carried out using an axisymmetric model of Al-SiC composite during electrical discharge machining (EDM). A FEA model of single spark EDM was developed to calculate the temperature distribution.Further, single spark model was extended to simulate the second discharge. For multi-discharge machining material removal was calculated by calculating the number of pulses. Validation of model has been done by comparing the experimental results obtained under the same process parameters with the analytical results. A good agreement was found between the experimental results and the theoretical value.

Keywords: Electrical Discharge Machining, FEA, Metal matrix composites, Multi-discharge

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1082663

References:

[1] W. König, "Machining of new materials", Annals CIRP vol. 39 (2), 1990, pp. 673-681.
[2] L. Cronjäger, "Machining of fibre and particle-reinforced aluminium", Annals CIRP vol. 41 (1), 1992, pp. 63-66.
[3] Allison JE and Cole GS, "Metal matrix composite in the automotive industry: opportunities and challenges", JOM Journal of the Minerals, Metals and Materials Society, January 1993, pp. 19-24.
[4] J. Li, B.Y. Zong, Y.M. Wang and W.B. Zhuang, "Experiment and modeling of mechanical properties on iron matrix composites reinforced by different types of ceramic particles", Materials Science and Engineering vol. A 527, 2010, pp. 7545-7551.
[5] P. Narender Singh, "Electric discharge machining of Al-10%SiCP ascast metal matrix composites", Journal of Materials Processing Technology, vol. 155-156, 2004, pp. 1653-1657.
[6] R. Komanduri, "Machining fiber-reinforced composites", Mech. Eng. , April 1993, pp. 58-64.
[7] F. Muller, "Non-conventional machining of particle reinforced metal matrix composite", International Journal of Machine Tools & Manufacture,vol. 40, 2000,pp. 1351-1366.
[8] SushantDhar, Rajesh Purohit, NishantSaini, Akhil Sharma and G. Hemath Kumar, "Mathematical modeling of electric discharge machining of cast Al-4Cu-6Si alloy-10wt.% SiCp composites", Journal of Materials Processing Technology, vol. 194, 2007, pp. 24-29.
[9] D. Kanagarajan, R. Karthikeyan, K. Palanikumar and J. Paulo Davim, "Optimization of electrical discharge machining characteristics of WC/Co composites using non-dominated sorting genetic algorithm (NSGA-II)", International Journal of Advance Manufacturing Technology, vol. 36, 2008, pp. 1124- 1132, DOI 10.1007/s00170-006- 0921-8.
[10] Witold We, glewski, Michal Basista, MarcinChmielewski and KatarzynaPietrzak, "Modeling of thermally induced damage in the processing of Cr-Al2O3composites", Composites: Part B, 2011, doi: 10.1 016/j.com positesb.20 11.07.0 16.
[11] Nilrudra Mandal, H. Roy, B. Mondal, N.C. Murmu, and S.K. Mukhopadhyay, "Mathematical Modeling of Wear Characteristics of 6061 Al-Alloy-SiCp Composite Using Response Surface Methodology", Journal of Materials Engineering and Performance, DOI: 10.1007/s11665-011-9890-7.
[12] D.S. Kumar, Heat and Mass Transfer, 10th edition, S.K. Kataria& Sons, Delhi, 2000.
[13] M. Kunieda, K. Yanatori, "Study on debris movement in EDM gap, International Journal of Electrical Machining",vol. 2, 1997, pp. 43-49.
[14] Y.F. Luo, "The dependence of interspace discharge transitivity upon the gap debris in precision electro-discharge machining", Journal ofMaterials Processing Technology,vol. 68, 1997, pp. 127-131.
[15] K Furutani, A. Saneto, H. Takezawa, N. Mohri, H. Miyake, "Accertation of titanium carbide by electrical discharge machining with powdersuspended in working fluid", Precision Engineering vol. 25, 2001,pp. 138-144.
[16] Yih-fongTzeng and Chen Fu-chen, "A simple approach for robust design of high-speed electrical-discharge machining technology", InternationalJournal of Machine Tool & Manufacture vol. 43, 2003, pp. 217-227.
[17] D. D. Dibitono and P. T. Eubank, "Theoretical model of the electrical discharge machining process I. A Simple Cathode erosion model," Journal of Applied Physics, vol. 66, 1989, pp. 4095-4103.
[18] M. R. Patel, B. A. Maria, P. T. Eubank and D.D. Dibitonto, "Theoretical models of the electrical discharge machining process. II. The anode erosion model," Journal of Applied Physics, vol. 66/9, 1989, pp. 4104.
[19] P. T. Eubank and M. R. Patel, "Theoretical models of the electrical discharge machining process.III. The variable mass, cylindrical plasma model," Journal of Applied Physics, vol. 73/11, 1993, pp. 7900-7909.
[20] R.Bhattacharya, V.K.Jain and P.S.Ghoshdastidar,"Numerical Simulation of Thermal Erosion in EDM Process", Journal of the Institution of Engineers (India), Production Engineering Division, Vol.77, 1996, pp.13-19.
[21] V. Yadav, V. Jain and P. Dixit, "Thermal stresses due to electrical discharge machining", International Journalof Machine Tools Manufacturing, vol. 42, 2002, pp. 877-888.
[22] P. Shankar, V.K. Jain and T. Sundarajan, "Analysis of spark profiles during EDM process", Machining Science Technology, vol. 1 (2), 1997, pp. 195-217.
[23] A. Erden, "Effect of materials on the mechanism of electric discharge machining (EDM)", Transactions of ASME, Journal of Engineering Materials and Technology vol. 108, 1983, pp. 247-251.
[24] K. Salonitis, A. Stournaras, P. Stavropoulos and G. Chryssolouris, "Thermal modeling of the material removal rate and surface roughness for die-sinking EDM", International Journal of Advanced Manufacturing Technology, vol. 40, 2009, pp. 316 - 323.
[25] A. Dvivedi "Experimental investigation and optimisation in EDM of Al 6063 SiCp metal matrix composite", International Journal of Machining and Machinability of Materials, Vol. 3, Nos. 3/4, 2008,pp. 293-308.