Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

IF 0.6 4区 材料科学 Q4 METALLURGY & METALLURGICAL ENGINEERING
Prabu Rajendran, Velmurugan Duraisamy, Ashok Raj Rajendran, Raja Velur Loganathan
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引用次数: 0

Abstract

The need to optimize the process parameters in Electrical Discharge Machining (EDM) for aged AA7075 Metal Matrix Composites (AAMMCs) is evident as it impacts various aspects such as mechanical properties, tool wear, surface finish, integrity, precision, accuracy, process stability, process consistency, and cost-effectiveness. In this study, aluminium alloy AA7075 was chosen as the matrix material because of the need to enhance its mechanical properties. Titanium Carbide (TiC) was chosen as the reinforcing material owing to its superior mechanical properties. Therefore, TiC holds the capability to improve the mechanical attributes of AA7075. The selection of the stir cast method for the manufacturing of AA7075/TiC (0, 4, 8, 12, and 16 wt.%) was based on its ease of fabrication, ability to achieve a uniform distribution of reinforcements, reduced susceptibility to oxidation and porosity, and improved control over the microstructure. This AA7075/12wt.%TiC MMC underwent an aging process at 520 °C for 180 min and was subsequently cooled within the furnace environment. The density of the aged and non-aged AA7075/TiC-based composites was determined through a density test using the Archimedes’ principle. Microhardness testing was conducted on the non-aged and aged AA7075-based MMCs employing a Vickers microhardness tester. Tensile strength and compressive strength of the aged and non-aged AA7075-based MMCs were determined by the usage of a universal testing machine (UTM) and a compression testing machine (CTM). The optimal combination of the manufactured AA7075/TiC MMCs was determined based on their mechanical properties. The most effective combination was identified as AA7075/12wt.%TiC MMC due to its superior values in hardness, tensile strength, compressive strength, and density compared to other combinations. The aging process aimed to enhance the mechanical properties without the need for additional reinforcements. EDAX and X-ray Diffraction Analysis (XRD) tests were employed to determine the weight percentage of the matrix and reinforcements and to identify the formation of precipitates in the AA7075/12wt.%TiC composites. The SEM equipment was utilized to verify the uniform distribution of titanium carbide in the matrix material AA7075. Optimization of EDM process parameters for aged AA7075/12wt.%TiC composite was carried out using Taguchi design-based Grey Relational Analysis (GRA). The selected input parameters for the optimization included the chromium concentration (g×l-1), current (amps) and pulse-on time (µs). The response parameters chosen for optimization were surface roughness (SR) and tool wear rate (TWR). The sequence of influencing EDM input parameters is chromium concentration, pulse on time and current. The optimized EDM process parameters were 8 g×l-1 chromium concentration, 5 amps current and 240 µs pulse on time and the corresponding response were 0.198 TWR and 1.56 SR.
老化 AA7075/TiC 金属基复合材料的放电加工 (EDM) 工艺参数优化
老化 AA7075 金属基复合材料(AAMMC)的放电加工(EDM)工艺参数对机械性能、刀具磨损、表面光洁度、完整性、精度、准确性、工艺稳定性、工艺一致性和成本效益等多方面都有影响,因此优化其工艺参数的必要性显而易见。本研究选择 AA7075 铝合金作为基体材料,因为需要提高其机械性能。由于碳化钛 (TiC) 具有优异的机械性能,因此被选为增强材料。因此,TiC 能够改善 AA7075 的机械属性。之所以选择搅拌铸造法制造 AA7075/TiC(0、4、8、12 和 16 wt.%),是因为这种方法易于制造,能够实现增强材料的均匀分布,降低氧化和气孔的易感性,并改善对微观结构的控制。AA7075/12wt.%TiC MMC 在 520 °C 下进行了 180 分钟的老化处理,随后在炉内冷却。老化和未老化 AA7075/TiC 复合材料的密度是通过使用阿基米德原理的密度测试确定的。使用维氏硬度计对未老化和老化的 AA7075 基 MMC 进行了显微硬度测试。使用万能试验机(UTM)和压缩试验机(CTM)测定了老化和未老化 AA7075 材料的抗拉强度和抗压强度。根据机械性能,确定了 AA7075/TiC 混合材料的最佳组合。与其他组合相比,AA7075/12wt.% TiC MMC 的硬度、抗拉强度、抗压强度和密度都更高,因此被认为是最有效的组合。老化过程旨在提高机械性能,而不需要额外的增强材料。采用 EDAX 和 X 射线衍射分析 (XRD) 测试确定基体和增强材料的重量百分比,并确定 AA7075/12wt.%TiC 复合材料中沉淀物的形成。利用扫描电镜设备验证了碳化钛在基体材料 AA7075 中的均匀分布。使用基于田口设计的灰色关系分析法(GRA)对老化 AA7075/12wt.%TiC 复合材料的放电加工工艺参数进行了优化。优化所选的输入参数包括铬浓度(克×升-1)、电流(安培)和脉冲开启时间(微秒)。优化所选的响应参数为表面粗糙度(SR)和刀具磨损率(TWR)。影响放电加工输入参数的顺序是铬浓度、脉冲导通时间和电流。优化后的放电加工工艺参数为 8 g×l-1 铬浓度、5 安培电流和 240 µs 脉冲开启时间,相应的响应为 0.198 TWR 和 1.56 SR。
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来源期刊
Revista De Metalurgia
Revista De Metalurgia 工程技术-冶金工程
CiteScore
1.30
自引率
25.00%
发文量
18
审稿时长
>12 weeks
期刊介绍: Revista de Metalurgia is a bimonhly publication. Since 1998 Revista de Metalurgia and Revista Soldadura have been combined in a single publicación that conserves the name Revista de Metalurgia but also includes welding and cutting topics. Revista de Metalurgia is cited since 1997 in the ISI"s Journal of Citation Reports (JCR) Science Edition, and in SCOPUS.
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