Sunteți pe pagina 1din 25

Accepted Manuscript

Influence of Wire EDM parameters on the Damping Behaviour of A356.2 Aluminum


Alloy

Dora Siva Prasad, Chintada Shoba, K.Rahul Varma, Abdul Khurshid

PII: S0925-8388(15)30163-8
DOI: 10.1016/j.jallcom.2015.06.050
Reference: JALCOM 34389

To appear in: Journal of Alloys and Compounds

Received Date: 28 March 2015


Revised Date: 18 May 2015
Accepted Date: 5 June 2015

Please cite this article as: D.S. Prasad, C. Shoba, K.R. Varma, A. Khurshid, Influence of Wire EDM
parameters on the Damping Behaviour of A356.2 Aluminum Alloy, Journal of Alloys and Compounds
(2015), doi: 10.1016/j.jallcom.2015.06.050.

This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to
our customers we are providing this early version of the manuscript. The manuscript will undergo
copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please
note that during the production process errors may be discovered which could affect the content, and all
legal disclaimers that apply to the journal pertain.
ACCEPTED MANUSCRIPT

Influence of Wire EDM parameters on the Damping Behaviour of A356.2


Aluminum Alloy

Dora Siva Prasad1*, Chintada Shoba2, K. Rahul Varma3, Abdul Khurshid4


1*
Dept of Mechanical Engineering, GITAM University, Visakhapatnam, 530045, INDIA,

PT
Email: dorasivaprasad@gmail.com, Ph: +919848480122
2
Dept of Industrial Engineering, GITAM University, Visakhapatnam, 530045, INDIA
3
Dept of Mechanical Engineering, RAGHU College of Engineering, Visakhapatnam, INDIA
4
M.Tech (CAD/CAM), Dept of Mechanical Engineering, GITAM University, Visakhapatnam, 530045, INDIA,

RI
Abstract

SC
The effect of different Wire electrical discharge machining (WEDM) process parameters

on the damping behavior of A356.2 aluminum alloy is investigated. In the present investigation

U
pulse on time (TON), pulse off time (TOFF) and peak current (IP) which are considered to be the
AN
most significant process parameters from the previous studies are varied using one factor at a

time approach, to study the effect on damping behavior of A356.2 aluminum alloy. Damping
M

experiments are performed on a dynamic mechanical analyzer (DMA 8000) at constant strain
D

under dual cantilever mode over a frequency range of 1 to 100 Hz at room temperature. The
TE

scanning electron microscope was used for characterization of the wire EDMed samples.

Experimental results reveal that the damping behavior greatly depends on the wire EDM process
EP

parameters. The related mechanisms are presented.

Keywords: A: Metals and alloys, B: Mechanical alloying C: Mechanical properties D: SEM,


C

A356.2 aluminum alloy.


AC

1. Introduction

Damping is a phenomenon by which mechanical energy is dissipated (usually converted

as thermal energy) during cyclic loading. For human comfort and safe operating conditions, high

damping capacity is desirable to suppress mechanical vibrations. As stated by Lavernia et al,

1
ACCEPTED MANUSCRIPT

aluminum alloys, are limited in their application and performance in a dynamic environment

because of low damping capacity [1]. James Cox et al [2] has studied that the damping behavior

of A356 aluminum alloy at a constant frequency of 1 Hz in the temperature range of 35–510°C

under three-point bending method using dynamic mechanical analyzer. Results show that the

PT
damping capacity increases with temperature. A damping capacity of 0.014, 0.019, 0.120 at 50,

200, 400°C was reported in their study. Damping capacity of A356.2 aluminium alloy at room

RI
temperature in the frequency range of 1–25Hz has been studied by Prasad and Krishna [3].

SC
Results demonstrated that the damping capacity increases with the increase in the frequency. A

low damping capacity of 0.00549 at 1Hz was reported for A356.2 alloy. Experimental results of

U
Sudarshan and Surappa [4], revealed that the damping capacity of A356 aluminium alloy
AN
measured using dynamic mechanical analyzer at 10 Hz and at room temperature is 0.017. Yijie

Zhang et al [5] studied the damping behavior of A356 alloy after grain refinement. Experimental
M

results show that refined A356 alloy exhibits much higher damping capacity than that of A356
D

base alloy. They observed that the damping capacity of refined A356 alloy increased by
TE

8×10−3 compared to A356 base alloy which can be attributed to the change of Si size and grain

refinement. The damping behaviour of as cast and sintered aluminium has been investigated by
EP

Umashankar et al [6]. The results confirmed that sintered aluminium exhibit higher damping than

as cast aluminium which may be attributed to increased porosity.


C

The damping measurements, in general, were performed using dynamic mechanical


AC

analyzer and the samples (in particular metals and MMCs) for damping measurements will be

machined by the WEDM process as the thickness should be between 0.5 – 2.5 mm. WEDM is a

thermal machining process capable of accurately machining parts of hard materials with complex

shapes. Thin samples usually less than 3 mm can be easily machined by WEDM process, which

otherwise difficult to machine by other conventional machining process. WEDM process

2
ACCEPTED MANUSCRIPT

generates spark between a small wire electrode and a work piece in a dielectric medium, usually

water, which erodes the workpiece to produce complex shapes. Pulse on time, pulse off time,

peak current, pulse duration, pulse frequency, wire speed, wire tension, dielectric flow rate are

the machining parameters in WEDM.

PT
When the specimens are machined using the wire cut EDM process, white layer or recast

layer is a common phenomenon formed on the surface of the specimens which results from the melt

RI
of the material due to current from the process. Part of this melt is removed by the dielectric fluid and

SC
the remaining part re-solidifies rapidly on the surface of the specimens which results in the formation

of white layer. This white layer has a significant effect on the damping behaviour [7, 8]. As,

U
damping is the material's ability to dissipate elastic strain energy in the form of heat during
AN
cyclic loading to its surroundings, the white layer thus formed on the surface will act as a

protective layer to dissipate energy to the surroundings resulting lower damping capacities.
M

Conversely, when the specimens are machined by conventional machining process, the
D

temperature rise between the work piece and the tool is not significant and hence the possibility
TE

of the formation of the white layer is less. Hence, conventionally machined specimens exhibits

higher damping values [8].


EP

Several other investigators reported the influences of WEDM machining parameters on

the performance of a WEDM process [9-11]. Proper selection of WEDM parameters during actual
C

machining is of immense importance, to achieve the optimal performance. The effect of WEDM
AC

parameters like pulse-on time, pulse-off time, peak current and voltage on metal removal rate

(MRR) and surface roughness of hybrid composites has been investigated by Ramesh et al [12].

The results of ANOVA reveal the significance of the factors in the order pulse-on time, pulse-off

time, peak current. The effects of various process parameters of WEDM like pulse on time, pulse

off time, gap voltage, peak current, wire feed and wire tension on the material removal rate of

3
ACCEPTED MANUSCRIPT

hot die steel has been investigated by Singh and Garg [13]. Their findings reported that the MRR

increases with increase in pulse on time and peak current while decreases with increase in pulse

off time and voltage. Nihat Tosun et al [14] investigated on the effect and optimization of

machining parameters on the kerf (cutting width) and MRR in WEDM operations. Experiments

PT
were conducted under varying pulse duration, open circuit voltage, wire speed and dielectric

flushing pressure. The optimal parameters were determined by using Taguchi method. Han et al

RI
[15] experiments proved that the surface roughness can be improved by decreasing pulse on

SC
time, pulse off time and discharge current. The results also demonstrated that the same surface

roughness and different material removal rates are obtained when the pulse energy per discharge

U
is constant. Prohaszka et al [16] in their paper discussed about the effect of electrode material on
AN
machinability in wire EDM that will lead to the improvement of WEDM performance. The effect

of pulse on time, pulse off time, gap voltage, discharge current, wire tension and wire feed on
M

cutting velocity and surface roughness were studied using Taguchi’s orthogonal array by
D

Bagherian Azhiri et al [17]. Results reported that pulse on time and current were found to have a
TE

significant effect on cutting velocity and surface roughness. Al/SiC composites were machined

using WEDM and the effects of WEDM process parameters such as current, pulse on time and
EP

reinforcement percentage on surface finish and MRR has been investigated by Ashish Srivastava

et al [18]. Kapil Kumar et al [19] attempted to optimize the machining conditions for maximum
C

MRR and maximum surface finish. The effect of pulse peak current, pulse-on time, pulse-off
AC

time, wire feed, wire tension and flushing pressure on MRR and the surface finish has been

studied. The results confirmed that the MRR and surface finish was influenced more by pulse

peak current, pulse duration, pulse-off period and wire feed than by flushing pressure and wire

tension. Response surface methodology was used to optimize the process parameters during

machining of Al6061/SiC metal matrix composite using WEDM by Pragya Shandilya et al [20].

4
ACCEPTED MANUSCRIPT

Four input process parameters of WEDM (namely servo voltage, pulse-on time, pulse-off time

and wire feed rate) were chosen as variables to study the process performance in terms of cutting

width (kerf). Al2O3/6061Al composites were machined using WEDM to study the effect of

pulse-on time, on machining performance by Biing Hwa Yan et al [21]. Experimental results

PT
revealed that in order to prevent wire breakage, a very low wire tension, a high flushing rate and

a high wire speed were required. Also, an appropriate servo voltage, a short pulse-on time, and a

RI
short pulse-off time, which is normally associated with a high cutting speed, had little effect on

SC
the surface roughness. Ntasi et al. [22] presented a study to find the effect of electro discharge

machining on corrosion resistance of two types of dental alloys used for fabrication of implant

U
retained superstructures. They observed inferior corrosion resistance on EDMed components
AN
when compared to conventionally finished surfaces. The effect of wire-EDM cutting on fatigue

strength of a magnesium alloy at room temperature was investigated by Mohd Ahadlin Mohd
M

Daud et al [23]. The results showed that the fatigue limit of wire-EDM as-cut specimen is lower
D

as compared to smoothly polished specimens. Fatigue cracks are found to initiate and propagate
TE

to final failure from a cutting pit on the wire-EDM as-cut specimens.

From the above literature, it could be observed that the Wire EDM process parameters
EP

greatly influences on MRR, surface roughness, corrosion behavior and fatigue strength.

However, the effect of WEDM process parameters on the damping behavior of MMC was hardly
C

seen. Hence, it is necessary to study the effect of WEDM process parameters on the damping
AC

behavior and the researchers working on the damping behavior of metals or MMCs should be

considered for accurate damping values.

5
ACCEPTED MANUSCRIPT

2. Experimentation

2.1 Materials

The material used in this study was A356.2 aluminum alloy. Optical emission

spectroscopy is used to find the chemical composition of A356.2 aluminum alloy to confirm its

PT
composition ahead of experimentation. The chemical composition of A356.2 aluminum alloy is

given in Table 1.

RI
2.2 Sample preparation for damping measurements

SC
The specimens for damping measurements were machined by WEDM process. The

samples of required dimensions of 40 x 7 x 2 mm3 have been cut by using Electronica make

U
Wire Cut Electro Discharge Machining process. Various parameters varied during the
AN
experimentation are pulse on time (TON), pulse off time (TOFF) and peak current (IP). The effects

of these input parameters are studied on damping behaviour using one factor at a time approach.
M

The other parameters like wire feed rate, wire tension and spark gap voltage are taken as per the
D

machine setting. Wire feed rate, wire tension and spark gap voltage are considered as 10 m/min,
TE

10 Kgf, 1500 mm/min respectively. In each experiment one input parameter was varied while

keeping the other two parameters at some mean fixed value and the effect of change of the input
EP

variable on the damping behaviour is studied and reported in this paper. The process parameters

considered in the present work are presented in Table 2. In the first set of experiments TON is
C

varied from 105 to 111 µsec and the other parameters, TOFF and IP kept constant at 60 and 210
AC

units respectively. In the second set of experiments TOFF is varied from 57 to 63 µsec, keeping

constant values for TON and IP at 108 µsec and 210 A respectively. In the final set, IP is varied

from 190 to 230 A keeping constant values for TON and TOFF at 108 µsec and 60 µsec

respectively.

6
ACCEPTED MANUSCRIPT

2.3 Damping Measurements

The damping measurements of A356.2 alloy specimens are performed using a Dynamic

Mechanical Analyzer (DMA 8000). Tests were carried under a dynamic load of 2 N at room

temperature for the frequencies ranging from 1 Hz to 100 Hz at constant strain amplitude. The

PT
samples were loaded in dual cantilever arrangement. The tan δ and the storage modulus were

recorded as a function of temperature. The experimental setup along with the dual cantilever

RI
arrangement is shown in the Figure 1.

SC
3. Results

Figures 2 through 4 demonstrates the variation of damping capacity with frequency for

U
varied WEDM parameters. From all the plots it is observed that the damping capacity increases
AN
with frequency for all conditions studied here. The damping mechanism associated is attributed

to thermoelastic damping which is explained in the later section of the paper. TON is varied from
M

105 to 111 µsec keeping the other two parameters, namely TOFF (60 µsec) and peak current (210
D

A) at a constant value. The effect of TON on the damping capacity is studied and the variation
TE

with frequency is shown in Figure 2. From the plot it is observed that the damping capacity

increases with the increase in frequency. Also, it could be observed that the damping capacity
EP

was found to increase with the increase in TON. A maximum damping capacity of 0.022, 0.025

and 0.03 was noticed when the specimens were machined at 105, 108, 111 µsec of TON
C

respectively, which indicates that the damping capacity depends significantly on TON. An
AC

increase of 13% in damping was observed when TON increased from 105 to 108 µsec and an

increase of 20% is seen when TON increased from 108 to 111 µsec The effect of TOFF on the

damping capacity is shown in Figure 3. From the plots it is observed that the damping capacity

decreases with the increase in TOFF. A maximum damping capacity of 0.02, 0.017 and 0.015 was

seen when the specimens were machined at 57, 60, 63 µsec of TOFF i.e. the damping capacity

7
ACCEPTED MANUSCRIPT

decreased by 15% when TOFF changed from 57 to 60 µsec and a decrease of 11.7% is seen when

TOFF changed from 60 to 63 µsec. However, the damping capacity was found to increase with

frequency. Figure 4 shows the variation of damping capacity with frequency for the specimens

machined, keeping TOFF (60 µsec) and TON (108 µsec) constant and peak current varied from 230

PT
A to 190 A in steps of 20 A. From the graph, damping capacity is found to increase with

frequency and a marginal difference in the damping capacity has observed with varied peak

RI
current. It can be presumed that the damping capacity is almost independent with peak current

SC
for the machining conditions studied here and greatly depends on TOFF and TON. The maximum

damping values reported for these conditions are 0.0089, 0.009, 0.009 at 190, 210 and 230 A of

U
peak current. A comparison of damping capacities for all the specimens is presented in Figure 5.
AN
The increase/decrease in the damping capacity results from varied WEDM parameters, was

probably due to the formation of white layer which was discussed about in the following area of
M

the paper.
D

4. Discussions on the above results


TE

The results of the damping measurements show that the damping capacity of A356.2

aluminum alloy increases for all the specimens over the entire frequency range used in this study.
EP

The increase in damping capacity of A356.2 aluminum alloy can be ascribed to thermoelastic

damping. Thermoelastic damping is caused by the energy dissipated by irreversible heat flow
C

generated by stress-induced thermal gradients. In the present study, the damping measurements
AC

were performed using DMA in which the samples are subjected to heterogeneous deformation.

When the material undergoes a heterogeneous deformation, thermoelastic damping plays a

significant role in enhancement of damping capacity. When a beam is subjected to heterogeneous

deformation, one side of the beam is in tension gets slightly cooler and the other side is in

compression gets slightly warmer due to the coupled nature of the thermal and mechanical

8
ACCEPTED MANUSCRIPT

domains. This temperature gradient across the beam gives rise to heat flow to the surroundings

which is a direct measure of damping capacity. Also, According to the works of Ranjit Bauri and

Surappa [24] thermoelastic damping is the dominant damping mechanism observed beyond 20

Hz in the unreinforced alloy. In the present work, damping measurements were performed in the

PT
frequency range of 1 to 100 Hz and hence the increase in damping capacity can be ascribed to

thermoelastic damping.

RI
From the results it is noticed that the damping capacity greatly depends on TON. The

SC
increase in TON results an increase in damping capacity. TON is the amount of time current runs

into the gap before it turns off. Larger the TON, faster the cut was. When the TON is 111 µsec,

U
keeping other parameters constant, results in a cutting speed of 5.2 mm/min. It was noticed that
AN
when the TON is 108 µsec and 105 µsec, the cutting speed was reduced to 4.1 mm/min and 3

mm/min. As the wire passes through the material with high cutting speed, the surface near the
M

wire zone will melt the material quickly and solidifies within a short span of time which leads to
D

the formation of a thin white layer on the surface. On the other hand, as the cutting speed
TE

decreases, it forms a thick white layer on the surface due to slow solidification caused by the

high temperature in the wire. Hence, when the TON increases, cutting speed increases, which
EP

results in the decrease of the white layer thickness. As the thickness of white layer increases, the

damping capacity decreases. Figure 6 and 7 shows the cross sectional scanning electron
C

micrographs (SEM) of the white layer formed when the TON is 111 and 105 µsec respectively. It
AC

could be observed that, from figure 6, the average thickness of while layer is about 25 µm and

from figure 7, the average thickness of while layer is about 62.6 µm. As discussed earlier, the

white layer thus formed will act as a protective layer to dissipate energy to the surroundings

which is a direct measure of its damping capacity. Hence, more damping capacities were

reported for the specimens machined at maximum TON. Also, the bulk defects such as

9
ACCEPTED MANUSCRIPT

micropores and microcracks present on the surface will enhance the damping capacity [24]. The

SEM micrograph of the surface for the specimens machined at 111 µsec of TON is shown in

figure 8. Micrograph reveals the existence of cracks and pores on the surface of the white layer,

also results in higher damping capacities. For better understanding of this phenomenon, SEM

PT
micrographs are taken for the specimens machined by milling process. Figure 9 represents the

SEM micrograph on the surface of the milled specimen. It is clear that, the surface contains long

RI
ridges and grooves running parallel to the cutting direction with no evidence of cracks and pores.

SC
Results show that TOFF has a notable effect on the damping capacity. It was noticed that

the damping capacity decreases with the increase in TOFF. As the TOFF increases, cutting speed

U
decreases. It is noticed that the cutting speed decreased by 0.4 mm/min when the TOFF increases
AN
from 57 µsec to 60 µsec. Similarly, increase in TOFF from 60 µsec to 63 µsec, results in the

decrease of cutting speed by 0.4 mm/min. As the cutting speed decreases, the thickness of white
M

layer increases and hence lower damping capacities were reported at higher TOFF. Figure 10 and
D

11 show the cross sectional SEM micrographs of the sample machined at a TOFF of 63 µsec and
TE

57 µsec . It is evident from the micrographs that the average thickness of the white layer is about

79.1 µm and about 70.8 µm when the samples machined at a TOFF of 63 µsec and 57 µsec
EP

respectively. Also, from the micrograph the thickness of white layer was found to be even more

when compared with the specimens machined at varying TON and hence lower damping
C

capacities were noticed for the specimens machined at varying TON.


AC

From the results, it is noticed that peak current has no significant effect on the damping

behaviour. However, it was observed that the damping capacity increases with frequency. The

possible reason was outlined in the previous section. No significant decrease in the cutting speed

has been observed with the increase in the IP. The formation of white layer at a peak current of

190 A is shown in Figure 12. From the micrograph, it is clear that the thickness of the white

10
ACCEPTED MANUSCRIPT

layer is about 129 µm which is more when compared with the machining conditions discussed

above which results in lower damping values. Figure 13 shows the SEM micrograph on the

surface of the sample machined at a peak current of 190 A. Micrograph clearly showing that the

surface of the white layer contains a reduced number of pores and cracks which may also result

PT
in lower damping values.

RI
5. Conclusions

The effect of different WEDM process parameters on the damping behaviour of A356.2

SC
aluminum alloy is investigated in the present study. From the experimental results the following

conclusions are drawn.


U
The damping capacity of the A356.2 aluminium alloy increases with the increase in
AN
frequency for all the conditions studied here. Thermoelastic damping is the dominant

damping mechanism observed in the A356.2 aluminium alloy.


M

• Results of the tests undertaken in this study show that increasing TON increases the
D

damping capacity of aluminum alloy. This can be attributed to the decrease in the
TE

thickness of the white layer with the increase in TON. The decrease in thickness of the

white layer was probably due to the increase in cutting speed with the increase in TON.
EP

Increasing the TON results in the increase in the cutting speed by 1.1 mm/min. The

presence of a large number of microcracks and micropores on the surface of the white
C

layer also help in enhancing the damping capacity of the aluminum alloy.
AC

• The damping capacity was found to decrease with the increase in TOFF and this can be

ascribed to the increase in the thickness of the white layer with the increase in TOFF. The

increase in thickness of the white layer was probably due to the decrease in cutting speed

with the increase in TOFF. Increasing the TOFF results in the decrease in the cutting speed

by 0.4 mm/min.

11
ACCEPTED MANUSCRIPT

• The damping capacity was found to be almost independent of the peak current. The

increase in peak current will not alter the cutting speed and hence no significant change

in the white layer thickness, which could be the possible reason for no considerable

change in damping capacity with peak current.

PT
Acknowledgments

RI
The authors wish to thank the Department of Science and Technology, New Delhi, India

for financial support under Fast Track Proposals for Young Scientists Scheme (Grant No

SC
SB/FTP/ETA-0155/2013 dated 9th July2013).

U
References

[1] E.J. Lavernia, R.J. Perez, J. Zhang, Damping Behavior of Discontinuously Metal-Matrix
AN
Composites Reinforced AI Alloy, Metallurgical And Materials Transactions A, 26A, (1995),
M

2803-2818.

[2] James Cox, Dung D. Luong, Vasanth Chakravarthy Shunmugasamy, Nikhil Gupta, Oliver M.
D

Strbik, Kyu Cho, Dynamic and Thermal Properties of Aluminum Alloy A356/Silicon Carbide
TE

Hollow Particle Syntactic Foams, Metals, 4 (2014) 530-548.

[3] D. Siva Prasad and A. Rama Krishna, Effect of T6 heat treatment on damping characteristics
EP

of Al/RHA composites, Bulletin of Material Science, 35(6) (2012) 989–995.

[4] Sudarshan and M.K. Surappa, Synthesis of fly ash particle reinforced A356 Al composites
C

and their characterization. Materials Science & Engineering A, 480 (2008) 117-124.
AC

[5] Yijie Zhang, Naiheng Ma, Haowei Wang, Xianfeng Li, Study on damping behavior of A356

alloy after grain refinement, Materials and Design, 29(3) (2008) 706-708.

12
ACCEPTED MANUSCRIPT

[6] K. S. Umashankar, Abhinav Alva, K. V. Gangadharan Vijay Desai, Damping Behaviour of

Cast And Sintered Aluminium, ARPN Journal of Engineering and Applied Sciences, 4(6) (2009)

66-71.

[7] D. Siva Prasad and CH. Shoba, Effect of heat treatment on the white layer and its effect on

PT
the damping behavior of metal matrix composites, Materials Science & Engineering A, 591

(2014) 78–81.

RI
[8] D. Siva Prasad, CH. Shoba, B.S. Prasad, Effect of white layer on the damping capacity of

SC
metal matrix composites, Materials Science & Engineering A, 599 (2014) 25–27.

[9] R.E. Williams and K.P. Rajurkar, Study of Wire Electrical Discharge Machining Surface

U
Characteristics, Journal of Materials Processing Technology. 28 (1991) 486-493.
AN
[10] T.Sone, and K.Masui, Application of Ion Nitriding to Wire-Electrical-Discharge-Machined

Blanking Dies, Material Science and Engineering. 140(1991) 486-493.


M

[11] J.S Soni, G. Chakraverti, Machining Characteristics of Titanium with Rotary Electro-
D

Discharge Machining, Wear. 171(1994) 51-58.


TE

[12] S.Ramesh, N.Natarajan, V. Krishnaraj, Experimental investigation of A6061/SiC/B4C

hybrid MMC in Wire discharge machine, Indian journal of Engineering and Materials sciences.
EP

21(2014), 409-417.

[13] H. Singh and R. Garg, Effects of process parameters on material removal rate in WEDM,
C

Journal of Achievements in Materials and Manufacturing Engineering. 32(2009), 70-74.


AC

[14] N. Tosun, C. Cogun, G. Tosun, A study on kerf and material removal rate in wire electrical

discharge machining based on Taguchi method, Journal of Materials Processing Technology.

152 (2004) 316-322.

13
ACCEPTED MANUSCRIPT

[15] F. Han, J. Jiang, D. Yu, Influence of machining parameters on surface roughness in finish

cut of WEDM, The International Journal of Advanced Manufacturing Technology 34(2007) 538-

546

[16] J.Prohaszka, A.G. Mamalis and N.M.Vaxevanidis, The effect of electrode material on

PT
machinability in wire electro-discharge machining, Journal of Materials Processing technology.

69(1997) 233-237.

RI
[17] R. Bagherian Azhiri, R. Teimouri, M. Ghasemi Baboly, Z. Leseman, Application of

SC
Taguchi, ANFIS and grey relational analysis for studying, modeling and optimization of wire

EDM process while using gaseous media, International Journal of Advanced Manufacturing

Technology. 71(2014) 279–295.


U
AN
[18] Ashish Srivastava, Amit Rai Dixit, Sandeep Tiwari, Experimental Investigation of Wire

EDM Process Parameteres on Aluminum Metal Matrix Composite Al2024/SiC, International


M

Journal of Advance Research and Innovation. 2(2014) 511-515.


D

[19] Kapil Kumar and Sanjay Agarwal, Multi-objective parametric optimization on machining
TE

with wire electric discharge machining, International Journal of Advance Manufacturing

Technology 62(2012) 617–633.


EP

[20] Pragya Shandilya, P.K.Jain, N.K. Jain, Parametric optimization during wire electrical

discharge machining using response surface methodology, Procedia Engineering 38 (2012)


C

2371– 2377.
AC

[21] Biing Hwa Yan, Hsien Chung Tsai, Fuang Yuan Huang, Long Chorng Lee, Examination of

wire electrical discharge machining of Al2O3p/6061Al composites, International Journal of

Machine Tools & Manufacture. 45 (2005) 251–259.

[22] A. Ntasi W.D. Mueller, G. Eliades, Zinelis S, The effect of electro discharge machining

(EDM) on the corrosion resistance of dental alloys, Dental materials. 26(2010) 237-245.

14
ACCEPTED MANUSCRIPT

[23] Mohd Ahadlin Mohd Daud, Mohd Zaidi Omar, Junaidi Syarif Zainuddin Sajuri, Effect of

wire-edm cutting on fatigue strength of AZ61 Magnesium alloy, Jurnal Mekanikal, 30 (2010)

68–76.

[24] Ranjit Bauri and M.K. Surappa, Damping Behavior of Al-Li-SiCp Composites Processed by

PT
Stir Casting Technique, Metallurgical and Materials Transactions A, 36A (2005) 667-673.

RI
U SC
AN
M
D
TE
C EP
AC

15
ACCEPTED MANUSCRIPT

Table captions

Table 1: Chemical composition of A356.2 Al Alloy matrix


Table 2: Process parameters for WEDM

PT
Table 1: Chemical composition of A356.2 Al Alloy matrix

Si Fe Cu Mn Mg Zn Ni Ti

RI
6.5-7.5 0.15 0.03 0.10 0.4 0.07 0.05 0.1

SC
Table 2: Process parameters for WEDM

S.No TON (µsec) TOFF (µsec) IP (A)

U
1 111 63 230
AN
2 108 60 210
3 105 57 190
M
D
TE
C EP
AC

16
ACCEPTED MANUSCRIPT

Figure captions

Figure 1: DMA 8000 (PerkinElmer)


Figure 2: Tan δ (damping capacity) Vs Frequency for varying TON (TOFF 60 µsec, IP 210 A)
Figure 3: Tan δ (damping capacity) Vs Frequency for varying TOFF (TON 108 µsec, IP 210 A)

PT
Figure 4: Tan δ (damping capacity) Vs Frequency for varying IP (TON 108 µsec TOFF 60 µsec)
Figure 5: Comparison of tan δ with WEDM parameters
Figure 6: Cross sectional SEM micrograph showing white layer at TON 111 µsec,

RI
TOFF 57 µsec and IP 210 A
Figure 7: Cross sectional SEM micrograph showing white layer at TON 105 µsec,

SC
TOFF 57 µsec and IP 210 A
Figure 8: SEM micrograph of the surface at TON 111 µsec, TOFF 57 µsec and IP 210 A

U
Figure 9: SEM micrograph of the milled specimen
AN
Figure 10: Cross sectional SEM micrograph showing white layer at TOFF 63 µsec, TOFF 50 µsec
and IP 210 A
Figure 11: Cross sectional SEM micrograph showing white layer at IP 190 A,
M

TON 108 µsec and TOFF 63 µsec


Figure 12: SEM micrograph of the surface at IP 190 A, TON 108 µsec and TOFF 63 µsec
D
TE
C EP
AC

Figure 1: DMA 8000 (PerkinElmer)

17
ACCEPTED MANUSCRIPT

0.030 TON at 111


TON at 108
0.025 TON at 105

PT
0.020
Tan delta

RI
0.015

0.010

SC
0.005

U
0 20 40 60 80 100
AN
Frequency (Hz)

Figure 2: Tan δ (damping capacity) Vs Frequency for varying TON (TOFF 60 µsec, IP 210 A)
M

0.022
D

0.020
TOFF at 57
TE

0.018
TOFF at 60
0.016 TOFF at 63
0.014
EP

0.012
Tan delta

0.010
C

0.008
0.006
AC

0.004
0.002
0.000
0 20 40 60 80 100
Frequency (Hz)

Figure 3: Tan δ (damping capacity) Vs Frequency for varying TOFF (TON 108 µsec, IP 210 A)

18
ACCEPTED MANUSCRIPT

0.010
IP at 230
0.008 IP at 210
IP at 190

PT
0.006
Tan delta

0.004

RI
0.002

SC
0.000

0 20 40 60 80 100

U
AN Frequency (Hz)

Figure 4: Tan δ (damping capacity) Vs Frequency for varying IP (TON 108 µsec TOFF 60 µsec)
M

TON at 111, TOFF 60, IP 210 A


TON at 108, TOFF 60, IP 210 A
TON at 105, TOFF 60, IP 210 A
D

TOFF 63, TON 108, IP 210 A


0.030 TOFF 60, TON 108, IP 210 A
TOFF 57, TON 108, IP 210 A
TE

0.025 IP 230 A, TON 108, TOFF 60


IP 210 A, TON 108, TOFF 60
IP 190 A, TON 108, TOFF 60
0.020
EP
Tan delta

0.015
C

0.010
AC

0.005

0.000

0 20 40 60 80 100
Frequency (Hz)

Figure 5: Comparison of tan δ with WEDM parameters

19
ACCEPTED MANUSCRIPT

PT
RI
U SC
AN
Figure 6: Cross sectional SEM micrograph showing white layer at TON 111 µsec,
TOFF 57 µsec and IP 210 A
M
D
TE
C EP
AC

Figure 7: Cross sectional SEM micrograph showing white layer at TON 105 µsec,
TOFF 57 µsec and IP 210 A

20
ACCEPTED MANUSCRIPT

PT
RI
U SC
AN
Figure 8: SEM micrograph of the surface at TON 111 µsec, TOFF 57 µsec and IP 210 A
M
D
TE
C EP
AC

Figure 9: SEM micrograph of the milled specimen

21
ACCEPTED MANUSCRIPT

PT
RI
U SC
AN
Figure 10: Cross sectional SEM micrograph showing white layer at TOFF 63 µsec, TOFF 50 µsec
and IP 210 A
M
D
TE
C EP
AC

Figure 11: Cross sectional SEM micrograph showing white layer at TOFF 63 µsec, TOFF 50 µsec
and IP 210 A

22
ACCEPTED MANUSCRIPT

PT
RI
U SC
AN
Figure 12: Cross sectional SEM micrograph showing white layer at IP 190 A,
TON 108 µsec and TOFF 63 µsec
M
D
TE
C EP
AC

Figure 13: SEM micrograph of the surface at IP 190 A, TON 108 µsec and TOFF 63 µsec

23
ACCEPTED MANUSCRIPT

Highlights

• Damping capacity increase with the increase in frequency.


• Increasing pulse on time increases the damping capacity of aluminum alloy.

PT
• The damping capacity was found to decrease with the increase in pulse off time.
• No significant change in damping capacity was noticed with varied peak current.

RI
• The formation of white layer plays an important role in the damping behavior.

U SC
AN
M
D
TE
C EP
AC

S-ar putea să vă placă și