Mathematical Modeling and Finite Element Analysis of Wire Electro-Discharge Machining of Ceramic Particulate Reinforced Metal Matrix Composite Material

Indian Journal Of Science And Technology Pub Date : 2024-02-27 DOI:10.17485/ijst/v17i9.3131

A. S. Gore, Nilesh G Patil, Mohammed Naser Farooqui

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Abstract

Objectives: A mathematical model is formulated for WEDM process for machining of Al/SiC/p to predict crater size, material removal rate for single spark discharge and same model is extended for multiple spark discharges which is not extensively studied in the literature. This was done by considering previous experimental data from the literature. Methods: A mathematical model predicts heat flux, radius of crater, material removal rate. Mode of heat transfer considered as conduction through workpiece. Material modeling is done considering the number of reinforced particles in the given volume. For random distribution of reinforced particles, a code is written in MATLAB software tool. Co-ordinates of these reinforced particles are extracted for FEA simulation in ABAQUS software tool. Material properties are considered as temperature dependent. This methodology is not adopted for MMCs. Findings: Results of theoretical model, FEA simulation and experimentation are compared. The predicted MRR by FEA simulation is 2% error at lower Ton values as 0.2µs and 0.4 µs to that of experimental MRR. Novelty: Crater size becomes shallow with increase in volume percentage of SiC particles resulting greater crater radius. With increased pulse on time MRR increases up to certain limit and then decreases. Keywords: WEDM, Modeling, MMC, FEA, MRR

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陶瓷微粒增强金属基复合材料线电极放电加工的数学建模和有限元分析

目的：为加工 Al/SiC/p 的线切割机床工艺建立了一个数学模型，以预测单火花放电时的凹坑尺寸和材料去除率。这是通过考虑文献中以前的实验数据实现的。方法：数学模型可预测热通量、凹坑半径和材料去除率。热传导模式考虑为通过工件的传导。材料建模考虑了给定体积内的强化颗粒数量。针对强化颗粒的随机分布，使用 MATLAB 软件工具编写了代码。在 ABAQUS 软件工具中提取这些增强粒子的坐标进行有限元模拟。材料特性被认为与温度有关。这种方法不适用于 MMC。研究结果比较了理论模型、有限元分析模拟和实验结果。有限元分析模拟预测的 MRR 与实验 MRR 相比，在 Ton 值较低时（0.2µs 和 0.4µs 时），误差为 2%。新颖性：随着 SiC 颗粒体积百分比的增加，凹坑尺寸变浅，导致凹坑半径变大。随着脉冲导通时间的增加，MRR 会增加到一定限度，然后降低。关键词线切割机床建模 MMC 有限元分析 MRR

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Indian Journal Of Science And Technology

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