Investigating the Effect and Optimization of WEDM Parameters on LM26 Aluminium Alloy Hybrid Composites: An Response Surface Methodology Based Desirability Approach

IF 3.3 3区材料科学 Q3 CHEMISTRY, PHYSICAL

Silicon Pub Date : 2025-07-23 DOI:10.1007/s12633-025-03398-1

Vijayan S N, Samson Jerold Samuel Chelladurai, Saiyathibrahim A

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引用次数: 0

Abstract

This study seeks to optimize the Wire Electrical Discharge Machining (WEDM) parameters to improve the machining performance of hybrid MMCs based on LM26 aluminium alloy. The study focuses on the effects of three important WEDM parameters: current, idle time, and energy time. The process was modeled and optimized using Response Surface Methodology (RSM)-based Central Composite Design (CCD) in conjunction with a multi-objective desirability analysis. According to the experimental results, WWR ranged from 0.001 to 0.017, and Kw varied between 0.22468 mm and 0.38063 mm. Energy time and current were the two parameters that significantly affected Kw, while longer idle time reduced WWR because it improved cooling and effectively removed debris. With an Adjusted R² of 0.9605 and a Predicted R² of 0.8620, the analysis of variance validated the model’s dependability. 10.65 µs energy time, 11.904 µs idle time, and 4.15164 Amps current were found to be the ideal machining parameters, which led to an optimized Kw of 0.280582 mm and a minimized WWR of 0.00593563. High prediction accuracy was demonstrated by experimental validation, which revealed low error values for Kw (0.0096) and WWR (0.0423). The results highlight how stable, accurate, and effective machining of LM26-based hybrid MMCs can be accomplished with WEDM settings that are optimized. This supports high-precision applications in sectors where component reliability is crucial by improving dimensional accuracy and tool longevity.

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基于响应面法的理想性方法研究线切割工艺参数对LM26铝合金复合材料的影响及优化

本研究旨在优化线切割加工（WEDM）参数，以提高基于LM26铝合金的混合mmc的加工性能。研究重点是三个重要的电火花线切割参数：电流、空闲时间和能量时间的影响。采用响应面法（RSM）为基础的中心复合设计（CCD），结合多目标期望性分析，对该过程进行建模和优化。实验结果表明，wr变化范围为0.001 ~ 0.017，Kw变化范围为0.22468 ~ 0.38063 mm。能量时间和电流是两个显著影响Kw的参数，而更长的空闲时间降低了WWR，因为它改善了冷却并有效地去除了碎屑。调整后的R2为0.9605，预测的R2为0.8620，方差分析验证了模型的可靠性。10.65µs能量时间、11.904µs空闲时间和4.15164 Amps电流是理想的加工参数，优化后的Kw为0.280582 mm，最小的WWR为0.00593563。实验验证了该方法的预测精度，结果表明：Kw（0.0096）和WWR（0.0423）的误差值较低。结果表明，优化的电火花加工设置可以实现基于lm26的混合mmc的稳定、准确和有效的加工。通过提高尺寸精度和刀具寿命，这支持在部件可靠性至关重要的行业中的高精度应用。

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来源期刊

Silicon CHEMISTRY, PHYSICAL-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.90

自引率

20.60%

发文量

685

审稿时长

>12 weeks

期刊介绍： The journal Silicon is intended to serve all those involved in studying the role of silicon as an enabling element in materials science. There are no restrictions on disciplinary boundaries provided the focus is on silicon-based materials or adds significantly to the understanding of such materials. Accordingly, such contributions are welcome in the areas of inorganic and organic chemistry, physics, biology, engineering, nanoscience, environmental science, electronics and optoelectronics, and modeling and theory. Relevant silicon-based materials include, but are not limited to, semiconductors, polymers, composites, ceramics, glasses, coatings, resins, composites, small molecules, and thin films.