Parametric optimization of electro discharge machining for A356/TiB2 composite using neem oil dielectric: Machining performance and surface morphology analysis

IF 1.3 4区化学 Q4 CHEMISTRY, INORGANIC & NUCLEAR

Phosphorus, Sulfur, and Silicon and the Related Elements Pub Date : 2025-12-02 Epub Date: 2025-08-22 DOI:10.1080/10426507.2025.2551069

C. Rajaravi (Conceptualization Methodology Supervision Visualization Writing – review & editing) , U. Elaiyarasan (Conceptualization Investigation Methodology Project administration Validation Writing – original draft)

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引用次数: 0

Abstract

A356 is a lightweight and high-strength aluminum alloy with excellent corrosion resistance, widely used in aerospace, automotive, and marine applications. However, machining of titanium diboride (TiB₂)-reinforced A356 aluminum alloy using unconventional machining methods remains challenging due to the high thermal conductivity and low electrical conductivity, affecting machining efficiency and surface integrity. This study investigates electrical discharge machining (EDM) of A356-10TiB₂ composite fabricated via stir casting, using neem oil dielectric fluid. The composite exhibited a hardness of 78.33 BHN. The EDM process was optimized using response surface methodology (RSM) to minimize surface roughness (SR) and maximize material removal rate (MRR) by varying supplied current (SC), pulse on time (T_on), and pulse off time (T_off). The correlation coefficients for MRR and SR were 99.07% and 99.91%, respectively. MRR and SR initially increased with SC, T_on, and T_off but decreased at higher levels. Higher SC and T_on increased ionization temperature, enhancing MRR, while lower values caused cracks and globules. Optimal parameters (SC = 10 A, T_on = 62 µs, T_off = 7 µs) yielded a maximum MRR of 0.211 g/min and minimum SR of 4.34 µm. The optimization error was 1.9% (MRR) and 3.97% (SR), with desirability score of 0.9865 confirming the reliability of the models.

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印楝油介质下A356/TiB2复合材料电火花加工参数优化：加工性能及表面形貌分析

A356是一种轻质高强铝合金，具有优异的耐腐蚀性，广泛用于航空航天，汽车和船舶应用。然而，采用非常规的加工方法加工二硼化钛（TiB2）增强A356铝合金，由于其高导热性和低导电性，影响了加工效率和表面完整性，仍然具有挑战性。研究了搅拌铸造A356-10TiB2复合材料在印楝油介质下的电火花加工。复合材料的硬度为78.33 BHN。利用响应面法（RSM）优化电火花加工工艺，通过改变供电电流（SC）、脉冲接通时间（Ton）和脉冲关闭时间（Toff）来最小化表面粗糙度（SR）和最大化材料去除率（MRR）。MRR和SR的相关系数分别为99.07%和99.91%。MRR和SR最初随着SC、Ton和Toff的增加而增加，但随着SC、Ton和Toff的增加而降低。较高的SC和Ton增加了电离温度，提高了MRR，而较低的SC和Ton则导致了裂缝和球团。最佳参数（SC = 10 A, Ton = 62µs, Toff = 7µs）的最大MRR为0.211 g/min，最小SR为4.34µm。优化误差为1.9% （MRR）和3.97% (SR)，理想评分为0.9865，证实了模型的可靠性。

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来源期刊

Phosphorus, Sulfur, and Silicon and the Related Elements 化学-无机化学与核化学

CiteScore

2.60

自引率

7.70%

发文量

103

审稿时长

2.1 months

期刊介绍： Phosphorus, Sulfur, and Silicon and the Related Elements is a monthly publication intended to disseminate current trends and novel methods to those working in the broad and interdisciplinary field of heteroatom chemistry.