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PII: S0925-8388(15)30163-8
DOI: 10.1016/j.jallcom.2015.06.050
Reference: JALCOM 34389
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.
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Email: dorasivaprasad@gmail.com, Ph: +919848480122
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Dept of Industrial Engineering, GITAM University, Visakhapatnam, 530045, INDIA
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Dept of Mechanical Engineering, RAGHU College of Engineering, Visakhapatnam, INDIA
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M.Tech (CAD/CAM), Dept of Mechanical Engineering, GITAM University, Visakhapatnam, 530045, INDIA,
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Abstract
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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
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pulse on time (TON), pulse off time (TOFF) and peak current (IP) which are considered to be the
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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
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experiments are performed on a dynamic mechanical analyzer (DMA 8000) at constant strain
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under dual cantilever mode over a frequency range of 1 to 100 Hz at room temperature. The
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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
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1. Introduction
as thermal energy) during cyclic loading. For human comfort and safe operating conditions, high
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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
under three-point bending method using dynamic mechanical analyzer. Results show that the
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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
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temperature in the frequency range of 1–25Hz has been studied by Prasad and Krishna [3].
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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
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Sudarshan and Surappa [4], revealed that the damping capacity of A356 aluminium alloy
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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
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results show that refined A356 alloy exhibits much higher damping capacity than that of A356
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base alloy. They observed that the damping capacity of refined A356 alloy increased by
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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
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Umashankar et al [6]. The results confirmed that sintered aluminium exhibit higher damping than
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
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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
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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
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of the material due to current from the process. Part of this melt is removed by the dielectric fluid and
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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,
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damping is the material's ability to dissipate elastic strain energy in the form of heat during
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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.
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Conversely, when the specimens are machined by conventional machining process, the
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temperature rise between the work piece and the tool is not significant and hence the possibility
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of the formation of the white layer is less. Hence, conventionally machined specimens exhibits
the performance of a WEDM process [9-11]. Proper selection of WEDM parameters during actual
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machining is of immense importance, to achieve the optimal performance. The effect of WEDM
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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
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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
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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
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[15] experiments proved that the surface roughness can be improved by decreasing pulse on
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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
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is constant. Prohaszka et al [16] in their paper discussed about the effect of electrode material on
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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
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cutting velocity and surface roughness were studied using Taguchi’s orthogonal array by
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Bagherian Azhiri et al [17]. Results reported that pulse on time and current were found to have a
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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
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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
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MRR and maximum surface finish. The effect of pulse peak current, pulse-on time, pulse-off
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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].
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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
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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
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short pulse-off time, which is normally associated with a high cutting speed, had little effect on
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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
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retained superstructures. They observed inferior corrosion resistance on EDMed components
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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
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Daud et al [23]. The results showed that the fatigue limit of wire-EDM as-cut specimen is lower
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as compared to smoothly polished specimens. Fatigue cracks are found to initiate and propagate
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From the above literature, it could be observed that the Wire EDM process parameters
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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
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seen. Hence, it is necessary to study the effect of WEDM process parameters on the damping
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behavior and the researchers working on the damping behavior of metals or MMCs should be
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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
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composition ahead of experimentation. The chemical composition of A356.2 aluminum alloy is
given in Table 1.
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2.2 Sample preparation for damping measurements
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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
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Wire Cut Electro Discharge Machining process. Various parameters varied during the
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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.
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The other parameters like wire feed rate, wire tension and spark gap voltage are taken as per the
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machine setting. Wire feed rate, wire tension and spark gap voltage are considered as 10 m/min,
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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
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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
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varied from 105 to 111 µsec and the other parameters, TOFF and IP kept constant at 60 and 210
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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.
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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
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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
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arrangement is shown in the Figure 1.
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3. Results
Figures 2 through 4 demonstrates the variation of damping capacity with frequency for
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varied WEDM parameters. From all the plots it is observed that the damping capacity increases
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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
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105 to 111 µsec keeping the other two parameters, namely TOFF (60 µsec) and peak current (210
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A) at a constant value. The effect of TON on the damping capacity is studied and the variation
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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
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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
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respectively, which indicates that the damping capacity depends significantly on TON. An
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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
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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
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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
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current. It can be presumed that the damping capacity is almost independent with peak current
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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
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peak current. A comparison of damping capacities for all the specimens is presented in Figure 5.
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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
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the paper.
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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.
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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
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generated by stress-induced thermal gradients. In the present study, the damping measurements
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were performed using DMA in which the samples are subjected to heterogeneous deformation.
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
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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
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frequency range of 1 to 100 Hz and hence the increase in damping capacity can be ascribed to
thermoelastic damping.
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From the results it is noticed that the damping capacity greatly depends on TON. The
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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,
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keeping other parameters constant, results in a cutting speed of 5.2 mm/min. It was noticed that
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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
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wire zone will melt the material quickly and solidifies within a short span of time which leads to
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the formation of a thin white layer on the surface. On the other hand, as the cutting speed
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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
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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
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micrographs (SEM) of the white layer formed when the TON is 111 and 105 µsec respectively. It
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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
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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
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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
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ridges and grooves running parallel to the cutting direction with no evidence of cracks and pores.
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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
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decreases. It is noticed that the cutting speed decreased by 0.4 mm/min when the TOFF increases
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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
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layer increases and hence lower damping capacities were reported at higher TOFF. Figure 10 and
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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
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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
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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
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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
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in lower damping values.
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5. Conclusions
The effect of different WEDM process parameters on the damping behaviour of A356.2
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aluminum alloy is investigated in the present study. From the experimental results the following
•
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The damping capacity of the A356.2 aluminium alloy increases with the increase in
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frequency for all the conditions studied here. Thermoelastic damping is the dominant
• Results of the tests undertaken in this study show that increasing TON increases the
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damping capacity of aluminum alloy. This can be attributed to the decrease in the
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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.
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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
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layer also help in enhancing the damping capacity of the aluminum alloy.
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• 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.
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• 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
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Acknowledgments
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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
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SB/FTP/ETA-0155/2013 dated 9th July2013).
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the damping behavior of metal matrix composites, Materials Science & Engineering A, 591
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[15] F. Han, J. Jiang, D. Yu, Influence of machining parameters on surface roughness in finish
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[16] J.Prohaszka, A.G. Mamalis and N.M.Vaxevanidis, The effect of electrode material on
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Taguchi, ANFIS and grey relational analysis for studying, modeling and optimization of wire
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[20] Pragya Shandilya, P.K.Jain, N.K. Jain, Parametric optimization during wire electrical
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[21] Biing Hwa Yan, Hsien Chung Tsai, Fuang Yuan Huang, Long Chorng Lee, Examination of
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[23] Mohd Ahadlin Mohd Daud, Mohd Zaidi Omar, Junaidi Syarif Zainuddin Sajuri, Effect of
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Table captions
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Table 1: Chemical composition of A356.2 Al Alloy matrix
Si Fe Cu Mn Mg Zn Ni Ti
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6.5-7.5 0.15 0.03 0.10 0.4 0.07 0.05 0.1
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Table 2: Process parameters for WEDM
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1 111 63 230
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2 108 60 210
3 105 57 190
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Figure captions
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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,
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TOFF 57 µsec and IP 210 A
Figure 7: Cross sectional SEM micrograph showing white layer at TON 105 µsec,
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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
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Figure 9: SEM micrograph of the milled specimen
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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,
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0.020
Tan delta
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0.015
0.010
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0.005
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0 20 40 60 80 100
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Frequency (Hz)
Figure 2: Tan δ (damping capacity) Vs Frequency for varying TON (TOFF 60 µsec, IP 210 A)
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0.022
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0.020
TOFF at 57
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0.018
TOFF at 60
0.016 TOFF at 63
0.014
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0.012
Tan delta
0.010
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0.008
0.006
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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)
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0.010
IP at 230
0.008 IP at 210
IP at 190
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0.006
Tan delta
0.004
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0.002
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0.000
0 20 40 60 80 100
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Figure 4: Tan δ (damping capacity) Vs Frequency for varying IP (TON 108 µsec TOFF 60 µsec)
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0.015
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0.010
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0.005
0.000
0 20 40 60 80 100
Frequency (Hz)
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Figure 6: Cross sectional SEM micrograph showing white layer at TON 111 µsec,
TOFF 57 µsec and IP 210 A
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Figure 7: Cross sectional SEM micrograph showing white layer at TON 105 µsec,
TOFF 57 µsec and IP 210 A
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Figure 8: SEM micrograph of the surface at TON 111 µsec, TOFF 57 µsec and IP 210 A
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Figure 10: Cross sectional SEM micrograph showing white layer at TOFF 63 µsec, TOFF 50 µsec
and IP 210 A
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Figure 11: Cross sectional SEM micrograph showing white layer at TOFF 63 µsec, TOFF 50 µsec
and IP 210 A
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Figure 12: Cross sectional SEM micrograph showing white layer at IP 190 A,
TON 108 µsec and TOFF 63 µsec
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Figure 13: SEM micrograph of the surface at IP 190 A, TON 108 µsec and TOFF 63 µsec
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Highlights
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• 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.
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• The formation of white layer plays an important role in the damping behavior.
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