Near Dry Powder Mixed Electric Discharge Machining of AA7050 Hybrid Composites Utilizing Composite Tool Materials

IF 0.7 4区材料科学 Q4 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Science Pub Date : 2024-05-07 DOI:10.5755/j02.ms.34795

Poniface JOSE ALOYSIUS, J. J. JEBEEN MOSES, Varghese Thaya Vijumon, Muthu Nadar FELEX XAVIER MUTHU

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引用次数: 0

Abstract

Electric Discharge Machining (EDM) is a prominent technique for producing components with complex geometry and intricate shapes. However, productivity depends on the selection of optimal input variables. This research investigates EDM and Near-Dry EDM (NDEDM) on AA7050 hybrid composites, exploring the impact of tool materials, Al2O3 powder concentration, and dielectric fluids on Material Removal Rate (MRR) and Surface Roughness (Ra). NDEDM offers a higher MRR due to localized heating and energy concentration, while hydrocarbon oil EDM provides lower Ra due to cooling and lubrication. Tool material properties, thermal conductivity and bonding strength, affect MRR and TWR. Aluminum composite tools via stir casting display a strong bonding interface, leading to efficient energy transfer and higher MRR, while copper composite tools via friction stir processing exhibit weaker bonding, potentially reducing MRR. Hydrocarbon oil significantly lowers TWR due to effective lubrication and cooling, while near dry EDM results in slightly higher TWR. Al2O3 powder enhances MRR, with an optimal concentration of 1 g/l, while higher concentrations hinder MRR. The presence of Al2O3 powder enhanced the surface quality by reducing the size of the recast layers and producing a smoother surface. Globules, craters, microcracks, pock marks and re-casted layers are the noticeable features spotted on the surface. The results were optimized using the TOPSIS optimization technique and process parameters 32 A current, 30 µs Ton, 3 mm gap distance machined under 3 g/l Al2O3 incorporated hydrocarbon oil dielectric medium using copper composites tool proffers optimal machining performance.

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利用复合工具材料对 AA7050 混合复合材料进行近干粉混合放电加工

放电加工（EDM）是生产具有复杂几何形状和错综复杂形状的部件的一项重要技术。然而，生产率取决于最佳输入变量的选择。本研究调查了 AA7050 混合复合材料上的电火花加工和近干式电火花加工 (NDEDM)，探讨了工具材料、Al2O3 粉末浓度和介电流体对材料去除率 (MRR) 和表面粗糙度 (Ra) 的影响。NDEDM 因局部加热和能量集中而具有更高的 MRR，而碳氢油 EDM 则因冷却和润滑而具有更低的 Ra。工具材料特性、导热性和结合强度会影响 MRR 和 TWR。通过搅拌铸造的铝复合材料工具显示出较强的结合界面，从而实现了高效的能量传递和较高的 MRR，而通过搅拌摩擦加工的铜复合材料工具则显示出较弱的结合强度，可能会降低 MRR。由于有效的润滑和冷却，碳氢化合物油明显降低了总功率因数，而近乎干式的电火花加工则略微提高了总功率因数。Al2O3 粉末可提高 MRR，最佳浓度为 1 克/升，而更高的浓度则会阻碍 MRR。Al2O3 粉末的存在可减少再铸层的尺寸，使表面更光滑，从而提高表面质量。表面出现的明显特征是球状、凹坑、微裂纹、麻点和重铸层。使用 TOPSIS 优化技术对结果进行了优化，工艺参数为 32 A 电流、30 µs Ton、3 mm 间距，在 3 g/l Al2O3 掺杂碳氢化合物油介质条件下使用铜复合材料工具进行加工，可获得最佳加工性能。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Materials Science 工程技术-材料科学：综合

CiteScore

1.60

自引率

44.40%

发文量

审稿时长

4-8 weeks

期刊介绍： Materials Science reports on current research into such problems as cracking, fatigue and fracture, especially in active environments as well as corrosion and anticorrosion protection of structural metallic and polymer materials, and the development of new materials.