Wire EDM Mechanism of MMCs with the Variation of Reinforced Particle Size

The size of reinforced particles notably affects the electro-discharge machining (EDM) of metal matrix composites (MMCs). This paper explores the mechanism of wire EDM of MMCs with different sizes of reinforced particles as well as the corresponding unreinforced matrix material. The mechanisms of material removal, surface generation, and taper kerf formation were investigated. This study shows that the particles’ ability to protect matrix materials from the intense heat of electric arc controls the material removal rate, surface generation, and taper of kerf. The low melting point matrix material is removed very easily, but the heat resistance reinforced particles delay the removal of material and facilitate the transfer of the workpiece material to wire electrode and vice versa. Thus, the material stays longer in touch with intense heat and affects the surface generation, wire electrode wear, and width of the kerf

Machining of titanium alloy (Ti-6Al-4V) - theory to application

This paper correlates laboratory based understanding in machining of titanium alloys with theindustry based outputs and find possible solutions to improve machining efficiency oftitanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects ofchip formation mechanism and practical issues faced by industries during titaniummachining. This study also analyzed and linked the methods that effectively improve themachinability of titanium alloys. It is found that the deformation mechanism duringmachining of titanium alloys is complex and causes basic challenges, such as saw-toothchips, high temperature, high stress on cutting tool, high tool wear and undercut parts. Thesechallenges are correlated and affected by each other. Saw tooth-chips cause variation incutting forces which results in high cyclic stress on cutting tools. On the other hand, lowthermal conductivity of titanium alloy causes high temperature. These cause a favorableenvironment for high tool wear. Thus, improvements in machining titanium alloy dependmainly on overcoming the complexities associated with the inherent properties of this alloy.Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhancedmachining, hybrid machining and, use of high conductive cutting tool and tool holdersimprove the machinability of titanium alloy

Weldability of duplex stainless steel

Duplex stainless steels (DSSs) have many advantages due to the unique structural combination of ferrite and austenite grains. The structural change of these materials is very complex during welding, and it deteriorates the functional properties. This research investigates different welding processes such as laser beam, resistance, tungsten inert gas, friction stir, submerged arc, and plasma arc weldings considering the research available in the literature. The welding mechanism, change of material structure, and control parameters have been analyzed for every welding process. This analysis clearly shows that DSS melts in all most all welding processes, but the thermal cycle and maximum heat input are different. This difference affects the resulting structure and functional properties of the weld significantly

Microstructural and surface texture analysis due to machining in Super Austenitic Stainless Steel

Inferior surface quality is a significant problem faced by machinist. The purpose of this study is to present a surface texture analysis undertaken as part of machinability assessment of Super Austenitic Stainless Steel alloy-AL6XN. The surface texture analysis includes measuring the surface roughness and investigating the microstructural behaviour of the machined surfaces. Eight milling trials were conducted using combination of cutting parameters under wet machining. An optical profilometer (non-contact), was used to evaluate the surface texture at three positions. The surface texture was represented using the parameter, average surface roughness. Scanning Electron Microscope was utilised to inspect the machined surface microstructure and co relate with the surface roughness results. Results showed that maximum roughness values recorded at the three positions in the longitudinal direction (perpendicular to the machining grooves) were 1.21 μm (trial 1), 1.63 μm (trial 6) and 1.68 μm (trial 7) respectively whereas the roughness values were greatly reduced in the lateral direction. Also, results showed that the feed rate parameter significantly influences the roughness values compared to the other cutting parameters. The microstructure of the machined surfaces was distorted by the existence of cracks, deformed edges and bands and wear deposition due to machining process

Accuracy of duplex stainless steel feature generated by electrical discharge machining (EDM)

The present paper studies different types of errors generated on the feature (cylindrical holes) which was fabricated by the wire EDM of 2205 duplex stainless steel. Different experimental parameters such as, pulse on time, pulse off time and wire tension on the feature as well as the contribution of these parameters on cylindricity error, circularity error and diameter error were explored. Moreover, interactions among the input parameters were also considered. It was found that the total contributions of interactions between different parameters are reasonably high for all the cases which make the modelling process very complex for cylindricity, circularity and diameter errors in term of the range of parameter considered in this investigation. Wire tension has highest contribution on cylindricity error which is lowest at high value wire tension. Pulse on time has minor contribution on the cylindricity error and it increases with the increase of pulse on time. Pulse of time does not have any influence on the cylindricity error. The circularity error was lowest at medium pulse off time and medium wire tension; and those two parameters have almost similar and highest contributions. The pulse on time has around 14% contribution on circularity error and the medium value of it minimizes the circularity error. The input parameters such has pulse on time, pulse off time and wire tension have around 13%, 16% and 7% contributions respectively on diameter error which is minimized at medium pulse on time, and low pulse off time and low wire tension

Learning through projects in engineering education

[No abstract available

Stagnation zone during the turning of Duplex SAF 2205 stainless steels alloy

Duplex stainless alloys are extremely sensitive to cutting speed for strain hardening during machining. Tool wear for these materials is dominated by the adhesion wear because of formation of built-up edge (BUE) that upsurges the flank wear considerably. In addition, flute damage is a significant problem during drilling of those alloys. To address this issue, this paper investigates the mechanism of BUE creation in stagnation region of duplex SAF 2205 alloys during material removal by turning process. The investigation of chip root through SEM and electron backscatter diffraction (EBSD) revealed build-up of ferritic bands at the stagnation zone. Higher capacity of austenite phase to deform plastically is accountable for the ferrite build-up. This was detected as a possible activating mechanism of built-up edge. The flow pattern of austenite phase designates faster deforming compare to that of ferrite phases

Milling of Nanoparticles Reinforced Al-Based Metal Matrix Composites

This study investigated the face milling of nanoparticles reinforced Al-based metal matrix composites (nano-MMCs) using a single insert milling tool. The effects of feed and speed on machined surfaces in terms of surface roughness, surface profile, surface appearance, chip surface, chip ratio, machining forces, and force signals were analyzed. It was found that surface roughness of machined surfaces increased with the increase of feed up to the speed of 60 mm/min. However, at the higher speed (100–140 mm/min), the variation of surface roughness was minor with the increase of feed. The machined surfaces contained the marks of cutting tools, lobes of material flow in layers, pits and craters. The chip ratio increased with the increase of feed at all speeds. The top chip surfaces were full of wrinkles in all cases, though the bottom surfaces carried the evidence of friction, adhesion, and deformed material layers. The effect of feed on machining forces was evident at all speeds. The machining speed was found not to affect machining forces noticeably at a lower feed, but those decreased with the increase of speed for the high feed scenario

Measuring the Initial-Final Mass-Relation using wide double white dwarf binaries from Gaia DR3

The Initial-Final Mass-Relation (IFMR) maps the masses of main sequence stars to their white dwarf descendants. The most common approach to measure the IFMR has been to use white dwarfs in clusters. However, it has been shown that wide double white dwarfs can also be used to measure the IFMR using a Bayesian approach. We have observed a large sample of 90 Gaia double white dwarfs using FORS2 on the VLT. Considering 52 DA+DA, DA+DC, and DC+DC pairs, we applied our extended Bayesian framework to probe the IFMR in exquisite detail. Our monotonic IFMR is well constrained by our observations for initial masses of 1-5 Msun, with the range 1-4 Msun mostly constrained to a precision of 0.03 Msun or better. We add an important extension to the framework, using a Bayesian mixture-model to determine the IFMR robustly in the presence of systems departing from single star evolution. We find a large but uncertain outlier fraction of 59$\pm$21 percent, with outlier systems requiring an additional $0.70^{+0.40}_{-0.22}$ Gyr uncertainty in their cooling age differences. However, we find that this fraction is dominated by a few systems with massive components near 0.9 Msun, where we are most sensitive to outliers, but are also able to establish four systems as merger candidatesComment: Accepted for publication in MNRA

A preliminary assessment of machinability of titanium alloy Ti 6Al 4V during thin wall machining using trochoidal milling

Titanium alloys are of great demand in the aerospace and biomedical industries. Most the titanium products are either cast or sintered to required shape and finish machined to get the appropriate surface texture to meet the design requirements. Ti-6Al-4V is often referred as work horse among the titanium alloys due to its heavy use in the aerospace industry. This paper is an attempt to investigate and improve the machining performance of Ti-6Al-4V. Thin wall machining is an advance machining technique especially used in machining turbine blades which can be done both in a conventional way and using a special technique known as trochoidal milling. The experimental design consists of conducting trials using combination of cutting parameters such as cutting speed (vc), 90 and 120 m/min; feed/tooth (fz) of 0.25 and 0.35 mm/min; step over (ae) 0.3 and 0.2; at constant depth of cut (ap) 20mm and using coolant. A preliminary assessment of machinability of Ti-6Al-4V during thin wall machining using trochoidal milling is done. A correlation established using cutting force, surface texture and dimensional accuracy