Análisis de la integridad de la superficie y evaluación de la sostenibilidad en el mecanizado por electroerosión de un material compuesto de matriz metálica ingenieril Al-22% SiC

Subhashree Naik; Sudhansu Ranjan Das; Debabrata Dhupal; Ajit Kumar Khatua

doi:10.3989/revmetalm.210

Authors

Subhashree Naik Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha https://orcid.org/0000-0002-8456-4043
Sudhansu Ranjan Das Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha https://orcid.org/0000-0003-2723-4459
Debabrata Dhupal Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha https://orcid.org/0000-0001-9428-294X
Ajit Kumar Khatua Department of Mechanical Engineering, TempleCity Institute of Technology & Engineering, Khurda 752057, Odisha https://orcid.org/0000-0001-7278-3743

DOI:

https://doi.org/10.3989/revmetalm.210

Keywords:

Al-22%SiC MMC, Cost estimation, EDM, RSM, Surface finish, Sustainability

Abstract

In view of the widespread applications of engineered metal matrix composites, particularly in automobile, electricity, aerospace industries; the achievement of the desired form is a really tough challenge. This research addresses electrical discharge machining (EDM) of engineered Al-22%SiC metal matrix composite (MMC) to analyze the surface roughness of the machined parts. A series of machining trials are performed under varied process conditions (flushing pressure, gap voltage, pulse-on-time, discharge current, pulse-off-time) obtained by Box-Behnken design. Additionally, this work addresses on desirability optimization methodology and predictive modelling for the minimization of machined surface quality employing the response surface methodology (RSM). Based on the motivational viewpoint of “Go green-Think green-Act green”, a unique approach has been suggested for the economic analysis and the sustainability assessment to determine the overall machining cost per part and to justify the usefulness of vegetable oil as dielectric medium in the EDM process. According to this statistical analysis, the contribution of spark discharge current was identified as the leading factor in surface quality degradation. The estimated optimal surface roughness (Ra) value of 0.181 µm and the calculated overall machining cost per part of Rs. 245.9 (2.95 €) were preferred at pulse-on-time of 100 µs, gap voltage of 1 V, pulse-off-time of 30 µs, discharge current of 4 A and flushing pressure of 0.056 MPa, which indicates that it is techno-economically viable. The vegetable oil considered as dielectric fluid is biodegradable, environmentally safe and, thus, contributes to having a sustainable production. The Al-SiC MMC machining data would be beneficial to the industry.

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