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Modeling of machining parameters for MRR and TWR in EDM characteristics on Al/10 wt.-% TiB2 composites

Muthusamy Prabu, Subramaniam Magibalan, Chinnamuthu Senthilkumar, Rajagounder Palanivelu, Palanisamy Senthilkumar and Rajendran Boopathi
From the journal Materials Testing
https://doi.org/10.3139/120.111355

Abstract

This work was undertaken to study the effect of some of the main electro-discharge machining process parameters such as flushing pressure, current, pulse-on-time, and vibration on the tool wear rate (TWR), and metal removal rate (MRR) of Al 6061 alloy with 10 wt.-% TiB2p (titanium boride particulate) composites. The response surface methodology was used to determine the most important criteria to maximize the MRR and minimize the TWR. The experimental procedure was designed based on second-order rotatable central composite design. Sensitivity analysis was used to identify the important criteria and classify them by their order of importance in model validation. Many efforts were made to compare the calculated output of the data obtained. Pulse-on-time sensitivity was found to exert a more significant effect on MRR and TWR than did other criteria. The surface plots were prepared for both MRR and TWR. MRR value increases with an increase in peak current. It occurs in a workpiece that transfers the heat directly to the workpiece, and these functions increase TWR. This occurs because of an increase in MRR and a decrease in TWR.

*Correspondence Address, Associate Prof. Dr. M. Prabu, Department of Mechanical Engineering, K. S. R College of Engineering, Tiruchengode 637215, India, E-mail:

Dr. Muthusamy Prabu, born in 1981, received a PhD in Mechanical Engineering from Anna University, Tamil Nadu, India in 2016. He graduated with a Master's degree in Manufacturing Engineering from Annamalai University, Annamalai Nagar, Tamil Nadu, India in 2006, and with a Bachelor's degree in Mechanical Engineering from Bharathiar University, Tamil Nadu, India in 2004. He is currently working as Associate Professor in the Department of Mechanical Engineering at the K. S. R. College of Engineering, Tiruchengode, Tamil Nadu, India.

Prof. Subramaniam Magibalan, born in 1990, received a Master's degree in Engineering Design Engineering from K. S. Rangasamy college of Technology, Tiruchengode, Tamil Nadu, India in 2014. He obtained his Bachelor's degree in Mechanical Engineering at Karpagam college of Engineering, Tamil Nadu, India in 2008. He is currently working as Assistant Professor in the Department of Mechanical Engineering at the K. S. R. College of Engineering, Tiruchengode, Tamil Nadu, and India.

Dr. Chinnamuthu Senthilkumar, born in 1971, received a PhD in Manufacturing Engineering from Annamalai University, Annamalai Nagar, India, in 2011. He earned a Master's degree and a Bachelor's degree in Mechanical and Production Engineering from the same university in 2002 and 1993, respectively. He is currently working as Assistant Professor in the Department of Mechanical Engineering at the University College of Engineering in Panruti, Tamil Nadu, India.

Dr. Rajagoundar Palanivelu, received a PhD in Nano science and Technology from Anna university India, in 2015. He graduated with a M.Phil and M.Sc degree in Chemistry from Bharathiar university in 2003 and 1997, respectively. He is currently working as Professor and Head in the Department of Chemistry at K. S. Rangasamy College of Technology, Tiruchengode, Tamil Nadu, India.

Dr. Palanisamy Senthilkumar born in 1971 received a PhD in Cryogenic Engineering from IIT Madras, Chennai, India, in 2005. He graduated with a Master's degree in Mechanical Engineering from Bharathiyar University, Tamil Nadu, and India in 1997 and with a Bachelor's degree in Mechanical Engineering from AIME, Calcutta, India in 1994. He is currently working as Professor and Principal at K. S. R. College of Engineering, Tiruchengode, Tamil Nadu, India.

Dr. Rajendran Boopathi, born in 1978, received a PhD in Mechanical Engineering from Sathyabama University, Tamil Nadu, India in 2018. He graduated with a Master's degree in Manufacturing Engineering at Annamalai University, Tamil Nadu, India in 2006. He obtained his Bachelor's degree in Mechanical Engineering at the University of Madras, Chennai, Tamil Nadu, India in 2000. He is currently working as Associate Professor in the Department of Mechanical Engineering at Mahendra Engineering College, Mallasamudram, Tamil Nadu and India.

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Published Online: 2019-05-28
Published in Print: 2019-06-01

© 2019, Carl Hanser Verlag, München

From the journal
Materials Testing
Materials Testing
Volume 61 Issue 6

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