An effect of nano-SiC with different dielectric mediums on AZ61/7.5% B<sub>4</sub>C nanocomposites studied through electrical discharge machining and Taguchi based complex proportional assessment method

Selvarasu, Sakthi; Subramanian, Mahendran; Thangasamy, Jayasuthahar

doi:10.1590/1517-7076-RMAT-2023-0058

Sakthi Selvarasu

University College of Engineering, Department of Mechanical Engineering, 610204, Thirukkuvalai, Tamilnadu, India.

https://orcid.org/0000-0001-6855-9853

Mahendran Subramanian

University College of Engineering, Department of Mechanical Engineering, 610204, Thirukkuvalai, Tamilnadu, India.

Jayasuthahar Thangasamy

University College of Engineering, Department of Mechanical Engineering, 610204, Thirukkuvalai, Tamilnadu, India.

e-mail: sakthi.mech1990sss@gmail.com, mahendran200@gmail.com, jayasuthahar@gmail.com

Corresponding Author: Sakthi Selvarasu

MATERIALS	ELEMENTS	MG	AL	ZN	MN	SI	CU	FE	NI
AZ61	Wt.%	Bal	6.73	1.0	0.21	0.03	0.003	0.0035	0.007
Materials	Elements	Cu	Bi	0	Pb	–	–	–	–
Copper	Wt.%	99.90	0.0005	0.040	0.005	–	–	–	–

PROPERTIES	KEROSENE	SiC	B₄C	EDM OIL
Density (kg/m³)	860	3100	2520	835
Average particle size (nm)	–	85	100	–
Electrical conductivity (S/m)	50pS/m	70 - 140	100	400pS/m
Thermal conductivity (W/m K)	0.128	83.6	120 to 115	120
Specific heat (J/kg K)	2100	1040	950	1670
Melting point (^ºC)	–	2730	2350	–
Hardness (HK)	–	2100–3000	33GPa	–

FACTORS (UNITS/SYMBOL)	PROBLEMS FOUND USING BELOW LIMITS	LEVELS				FROM THE LITERATURE PAPERS/ MACHINE LIMITS/PROBLEMS FOUND USNG ABOVE LIMITS
FACTORS (UNITS/SYMBOL)	PROBLEMS FOUND USING BELOW LIMITS	1	2	3	4
Pulse duration (µs/T_on)	Electrode broken	20	40	60	80	On the basis of machine limit
Pulse interval (µs/T_off)	High SR	10	20	30	40	[²⁸[28] KAVIMANI, V., PRAKASH, K.S., THANKACHAN T., “Multi-objective optimization in WEDM process of graphene–SiC-magnesium composite through hybrid techniques”, Measurement, v. 145, pp. 335–349, 2019. doi: http://dx.doi.org/10.1016/j.measurement.2019.04.076. https://doi.org/10.1016/j.measurement.20... ]
Current (A/I)	Electrode broken	2	4	6	8	[³⁶[36] GOPALAKANNAN, S., SENTHILVELAN, T., “Application of response surface method on machining of Al–SiC nano-composites”, Measurement, v. 46, n. 8, pp. 2705–2715, 2013. doi: http://dx.doi.org/10.1016/j.measurement.2013.04.036. https://doi.org/10.1016/j.measurement.20... ]
Gap voltage (V/GV)	High process time	40	50	60	70	[³⁰[30] HOURMAND, M., FARAHANY, S., SARHAN, A.A., et al., “Investigating the electrical discharge machining (EDM) parameter effects on Al-Mg2Si metal matrix composite (MMC) for high material removal rate (MRR) and less EWR–RSM approach”, International Journal of Advanced Manufacturing Technology, v. 77, n. 5–8, pp. 831–838, 2015. doi: http://dx.doi.org/10.1007/s00170-014-6491-2. https://doi.org/10.1007/s00170-014-6491-... ]

S. NO.	PROCESS PARAMETERS				MRR (g/s) (X 10^–2)			EWR (g/s) (X 10^–2)			SURFACE ROUGHNESS (µm)
S. NO.	T_ON (µs)	T_OFF (µs)	I (A)	GV (V)	KEROSENE	EDM OIL	SIC + EDM OIL	KEROSENE	EDM OIL	SIC + EDM OIL	KEROSENE	EDM OIL	SIC + EDM OIL
1	1	1	1	1	0.130	0.136	0.180	0.198	0.188	0.173	1.431	1.231	1.071
2	1	2	2	2	0.171	0.180	0.237	0.189	0.179	0.165	1.891	1.626	1.415
3	1	3	3	3	0.242	0.254	0.335	0.188	0.179	0.165	2.671	2.297	1.998
4	1	4	4	4	0.244	0.256	0.338	0.162	0.154	0.142	2.692	2.315	2.014
5	2	1	2	3	0.246	0.274	0.377	0.246	0.226	0.195	2.721	2.068	1.737
6	2	2	1	4	0.284	0.315	0.435	0.232	0.214	0.184	3.136	2.384	2.002
7	2	3	4	1	0.311	0.345	0.476	0.155	0.143	0.123	3.433	3.192	2.682
8	2	4	3	2	0.317	0.352	0.486	0.151	0.139	0.120	3.503	3.013	2.531
9	3	1	3	4	0.320	0.388	0.539	0.238	0.207	0.162	3.536	2.970	2.465
10	3	2	4	3	0.337	0.408	0.567	0.226	0.197	0.153	3.719	3.124	2.593
11	3	3	1	2	0.359	0.434	0.604	0.268	0.233	0.182	3.962	3.328	2.762
12	3	4	2	1	0.390	0.472	0.655	0.185	0.161	0.125	4.302	3.614	3.000
13	4	1	4	2	0.390	0.461	0.654	0.241	0.198	0.142	4.309	3.491	2.862
14	4	2	3	1	0.401	0.473	0.672	0.238	0.195	0.141	4.427	3.586	2.941
15	4	3	2	4	0.407	0.480	0.682	0.261	0.214	0.154	4.492	3.639	2.984
16	4	4	1	3	0.436	0.514	0.730	0.215	0.177	0.127	4.812	3.897	3.196

SOURCE	DF	SEQ SS	ADJ SS	ADJ MS	F	P
MATERIAL REMOVAL RATE (g/s)
T^on	3	3.89E^–05	3.89E^–05	0.000013	114.48	0.001
T^off	3	3.1E^–06	3.1E^–06	0.000001	9.06	0.052
I	3	2E^–07	2E^–07	1E^–07	0.51	0.701
GV	3	0	0	0	0.04	0.989
Error	3	3E^–07	3E^–07	1E^–07
Total	15	4.25E^–05
S = 0.00033 R-Sq = 99.20% R-Sq(adj) = 96.00%
ELECTRODE WEAR RATE (g/s)
T^on	3	1E^–07	1E^–07	0	0.97	0.508
T^off	3	4E^–07	4E^–07	1E^–07	3.88	0.147
I	3	2E^–07	2E^–07	1E^–07	1.88	0.309
GV	3	1E^–07	1E^–07	0	1.14	0.459
Error	3	1E^–07	1E^–07	0
Total	15	8E^–07
S = 0.00017 R-Sq = 98.73% R-Sq(adj) = 93.65%
SURFACE ROUGHNESS (µm)
T^on	3	4.301	4.301	1.43367	59.99	0.004
T^off	3	1.13655	1.13655	0.37885	15.85	0.024
I	3	0.23737	0.23737	0.07912	3.31	0.176
GV	3	0.00708	0.00708	0.00236	0.1	0.955
Error	3	0.07169	0.07169	0.0239
Total	15	5.75369
S = 0.15 R-Sq = 98.75% R-Sq(adj) = 93.77%

S. NO.	PREDICTION USING QUADRATIC MODEL			ERROR % IN ACTUAL VS QUADRATIC MODEL
S. NO.	MRR	EWR	SR	MRR	EWR	SR
1	0.00174	0.00172	1.031	0.00005	0.00000	0.040
2	0.00256	0.00171	1.537	–0.00019	–0.00006	–0.122
3	0.00314	0.00158	1.891	0.00021	0.00007	0.107
4	0.00342	0.00142	2.053	–0.00004	–0.00001	–0.039
5	0.00372	0.00189	1.733	0.00005	0.00006	0.003
6	0.00438	0.00185	2.003	–0.00003	–0.00001	–0.001
7	0.00479	0.00122	2.668	–0.00003	0.00000	0.014
8	0.00497	0.00127	2.505	–0.00011	–0.00007	0.026
9	0.00543	0.00168	2.470	–0.00004	–0.00006	–0.005
10	0.0056	0.00153	2.623	0.00006	0.00000	–0.031
11	0.00604	0.00182	2.745	–0.00001	0.00000	0.017
12	0.00645	0.00118	3.024	0.00010	0.00007	–0.024
13	0.00655	0.00139	2.847	–0.00001	0.00003	0.016
14	0.00674	0.00146	2.949	–0.00002	–0.00005	–0.008
15	0.00682	0.0015	2.960	0.00000	0.00004	0.023
16	0.00731	0.0013	3.213	–0.00001	–0.00003	–0.017

RESPONSES	QUADRATIC MODEL FACTORS
RESPONSES	MAPE	RMSE	R
Material Removal Rate	0.00001	0.00000	1.0000
Electrode Wear Rate	0.00000	0.00000	0.99937
Surface Roughness	0.06250	0.00000	0.99937

S. NO.	DECISION MATRIX			NORMALIZED MATRIX			WEIGHTED NORMALIZED MATRIX			BENEFICIAL CRITERIA, BI	NON-BENEFICIAL CRITERIA, CI	QI	UTILITY DEGREE, UD	RANK
S. NO.	MRR	EWR	SR	MRR	EWR	SR	MRR	EWR	SR	BENEFICIAL CRITERIA, BI	NON-BENEFICIAL CRITERIA, CI	QI	UTILITY DEGREE, UD	RANK
1	0.00180	0.00173	1.071	0.02255	0.07048	0.028	0.00902	0.02819	0.008	0.009	0.037	0.061	77.99	15
2	0.00237	0.00165	1.415	0.02980	0.06722	0.037	0.01192	0.02689	0.011	0.012	0.038	0.062	79.26	13
3	0.00335	0.00165	1.998	0.04208	0.06718	0.052	0.01683	0.02687	0.016	0.017	0.043	0.061	78.69	14
4	0.00338	0.00142	2.014	0.04242	0.05779	0.053	0.01697	0.02312	0.016	0.017	0.039	0.066	84.20	11
5	0.00377	0.00195	1.737	0.04738	0.07942	0.045	0.01895	0.03177	0.014	0.019	0.045	0.061	77.82	16
6	0.00435	0.00184	2.002	0.05462	0.07498	0.052	0.02185	0.02999	0.016	0.022	0.046	0.063	81.17	12
7	0.00476	0.00123	2.682	0.05978	0.05008	0.070	0.02391	0.02003	0.021	0.024	0.041	0.070	89.82	8
8	0.00486	0.00120	2.531	0.06100	0.04886	0.066	0.02440	0.01954	0.020	0.024	0.039	0.073	92.96	6
9	0.00539	0.00162	2.465	0.06761	0.06599	0.064	0.02704	0.02640	0.019	0.027	0.046	0.069	87.78	9
10	0.00567	0.00153	2.593	0.07111	0.06254	0.068	0.02844	0.02501	0.020	0.028	0.045	0.070	90.02	7
11	0.00604	0.00182	2.762	0.07575	0.07419	0.072	0.03030	0.02968	0.022	0.030	0.051	0.067	86.15	10
12	0.00655	0.00125	3.000	0.08226	0.05109	0.078	0.03290	0.02043	0.024	0.033	0.044	0.076	97.43	2
13	0.00654	0.00142	2.862	0.08209	0.05802	0.075	0.03284	0.02321	0.022	0.033	0.046	0.074	95.28	4
14	0.00672	0.00141	2.941	0.08433	0.05739	0.077	0.03373	0.02296	0.023	0.034	0.046	0.075	96.02	3
15	0.00682	0.00154	2.984	0.08557	0.06290	0.078	0.03423	0.02516	0.023	0.034	0.049	0.073	93.88	5
16	0.00730	0.00127	3.196	0.09166	0.05188	0.084	0.03666	0.02075	0.025	0.037	0.046	0.078	100.00	1

S. NO.	APPROACHES	SAMPLE/ELECTRODE MATERIALS/DIELECRIC MEDIUM	CONDITIONS	MRR (g/s)	EWR (g/s)	SR (µm)
[⁶⁷[67] ARUNKUMAR, L., RAGHUNATH, B.K., “Electro discharge machining characteristics of Mg/SiCP metal matrix composites by powder metallurgy (P/M) techniques”, IACSIT International Journal of Engineering and Technology, v. 5, n. 5, pp. 4332–4338, 2013.]	On increasing T^on	Mg/SiCp composites/Ø 10 mm Copper/Kerosene	T_on = 1000 µs, 200 µs T_off = 200 µs, 50 µs I = 10 A	0.0025	–	–
[³⁰[30] HOURMAND, M., FARAHANY, S., SARHAN, A.A., et al., “Investigating the electrical discharge machining (EDM) parameter effects on Al-Mg2Si metal matrix composite (MMC) for high material removal rate (MRR) and less EWR–RSM approach”, International Journal of Advanced Manufacturing Technology, v. 77, n. 5–8, pp. 831–838, 2015. doi: http://dx.doi.org/10.1007/s00170-014-6491-2. https://doi.org/10.1007/s00170-014-6491-... ]	RSM approach	Al–Mg2Si/ Ø 5.5 mm Copper/Oil	T_on = 200 µs I = 15 A SV = 50 V	0.0009	–	–
[⁶⁸[68] PONAPPA, K., SASIKUMAR, K.S.K., SAMBATHKUMAR, M., et al., “Multi-objective optimization of EDM process parameters for machining of hybrid aluminum metal matrix composites (al7075/tic/b4c) using genetic algorithm”, Surface Review and Letters, v. 26, n. 10, pp. 1950071, 2019. doi: http://dx.doi.org/10.1142/S0218625X19500719. https://doi.org/10.1142/S0218625X1950071... ]	GA approach	AA7075/2.5%TiC + 2.5%B₄C/Ø 7 mm Copper/Kerosene	T_on = 12 µs I = 10–20 A SV = 70 V	0.0031	0.0009	–
[⁶⁹[69] BODUKURI, A.K., KESHA, E., “Multi-attribute optimization of EDM process parameters for machining of SiC and B4C particle reinforced Al 6061 metal matrix composite adopting TOPSIS method”, International Journal of Advanced Technology and Engineering Exploration, v. 8, n. 79, pp. 735–752, 2021. doi: http://dx.doi.org/10.19101/IJATEE.2021.874132. https://doi.org/10.19101/IJATEE.2021.874... ]	TOPSIS approach	Al 6061+3% SiC+7 % B₄C/Ø 10 mm Copper/EDM oil	T_on = 20 µs I = 9 A T_off = 50 µs	0.0001	0.0003	4.108
[⁷⁰[70] ALAGARSAMY, S.V., RAVICHANDRAN, M., SARAVANAN, H., “Development of mathematical model for predicting the electric erosion behavior of TiO2 Filled Al-Zn-Mg-Cu (AA7075) alloy composite using RSM-DFA method”, Journal of Advanced Manufacturing Systems, v. 20, n. 01, pp. 1–26, 2021. doi: http://dx.doi.org/10.1142/S0219686721500013. https://doi.org/10.1142/S021968672150001... ]	RSM–DFA method	AA7075+10 wt.% TiO₂/ Ø 12 mm Brass/kerosene	T_on = 899 µs I = 14 A T_off = 30 µs	0.008	–	4.97
[⁷⁸[78] KUMARI, S., SONIA, P., SINGH, B., et al., “Optimization of surface roughness in EDM of pure magnesium (Mg) using TLBO”, Materials Today: Proceedings, v. 26, pp. 2458–2461, 2020. doi: http://dx.doi.org/10.1016/j.matpr.2020.02.523. https://doi.org/10.1016/j.matpr.2020.02.... ]	TLBO method	Mg/nil/nil	T_on = 40 µs I = 1 A T_off = 9 µs	–	–	2.4
[⁷⁹[79] ABDUL-RANI, A.M., RAZAK, M.A., LITTLEFAIR, G., et al., “Improving EDM process on AZ31 magnesium alloy towards sustainable biodegradable implant manufacturing”, Procedia Manufacturing, v. 7, pp. 504–509, 2017. doi: http://dx.doi.org/10.1016/j.promfg.2016.12.057. https://doi.org/10.1016/j.promfg.2016.12... ]	On adding Zinc particles	AZ31 Mg/copper/1 g/l zinc added dielectric medium	T_on = 16 µs I = 38 A T_off = 128 µs	–	–	5.77
[⁷¹[71] MEEL, R., SINGH, V., KATYAL, P., et al., “Optimization of process parameters of micro-EDD/EDM for magnesium alloy using Taguchi based GRA and TOPSIS method”, Materials Today: Proceedings, v. 51, pp. 269–275, 2022. doi: http://dx.doi.org/10.1016/j.matpr.2021.05.287. https://doi.org/10.1016/j.matpr.2021.05.... ]	GRA method	Mg/ Ø 0.5 mm Brass/Distilled water	T_on = 4 µs I = 5 A T_off = 3 µs	–	0.0187	–
[⁸⁰[80] RAZAK, M.A., ABDUL-RANI, A.M., RAO, T.V.V.L.N., et al., “Electrical discharge machining on biodegradable AZ31 magnesium alloy using Taguchi method”, Procedia Engineering, v. 148, pp. 916–922, 2016. doi: http://dx.doi.org/10.1016/j.proeng.2016.06.501. https://doi.org/10.1016/j.proeng.2016.06... ]	Taguchi method	AZ31 Mg/copper/kerosene	T_on = 16 µs I = 38 A SV = 80 V	–	–	6.50
[⁷²[72] SOMASUNDARAM, M., KUMAR, J.P., “Multi response optimization of EDM process parameters for biodegradable AZ31 magnesium alloy using TOPSIS and grey relational analysis”, Sadhana, v. 47, n. 3, pp. 1–14, 2022. doi: http://dx.doi.org/10.1007/s12046-022-01908-0. https://doi.org/10.1007/s12046-022-01908... ]	GRA and TOPSIS Approach	AZ31 Mg/copper/kerosene	T_on = 10 µs I = 3 A T_off = 5 µs	–	0.00007	3.2
Present work	On using COPRAS method	AZ61/7.5% B₄C composites/0.8 mm square copper electrode	T_on = 80 µs T_off = 40 µs I = 8 A GV = 60 V	0.00730	0.00127	3.196

{Y = β}_{0} {+ β}_{1} T_{on} {+ β}_{2} {I + β}_{3} T_{off} {+ β}_{4} {GV + β}_{5} T_{on}^{2} {+ β}_{6} I^{2} {+ β}_{7} T_{off}^{2} {+ β}_{8} {GV}^{2} {+ β}_{9} T_{on} {IT}_{off} {+ β}_{10} T_{on} {IGV + β}_{11} {IT}_{off} {GV + β}_{12} T_{off} {GVT}_{on}

R = 1 - \frac{\sum_{i = 1}^{n} [(C_{M o b s e r v e d i} - {\bar{C}}_{M o b d e r v e d})] [(C_{M p r e d i c t e d i} - {\bar{C}}_{M p r e d i c t e d})]}{\sqrt{\sum_{i = 1}^{n} (C_{M a c t u a l i} - C_{M M o d e l i})^{2} {\sum_{i = 1}^{n} (C_{M p r e d i c t e d i} - {\bar{C}}_{M p r e d i c t e d})}^{2}}}

D = [\begin{matrix} x_{11} & x_{12} \dots & x_{1 n} \\ x_{21} & x_{22} \dots & x_{2 n} \\ ⋮ & ⋮ ⋮ & ⋮ \\ ⋮ & ⋮ ⋮ & ⋮ \\ ⋮ & ⋮ ⋮ & ⋮ \\ x_{m 1} & x_{n 2} \dots & x_{m n} \end{matrix}]

MRR = 0.00092 + 0 {.00011T}_{on} + 9 {.66E}^{- 05} T_{off} + 6 {.2E}^{- 05} I - 2 {.3E}^{- 05} GV - 3 {.2E}^{- 07} T_{on}^{2} - 3 {.1E}^{- 07} T_{off}^{2} + 5 {.12E}^{- 06} I^{2} + 3 {.5E}^{- 07} {GV}^{2} - 3 {.1E}^{- 08} T_{on} T_{off} I - 7 {.1E}^{- 09} T_{on} IGV - 6 {.4E}^{- 08} T_{off} IGV + 7 {.43E}^{- 10} {IGVT}_{on}

EWR = 0.000295 + 2 {.58E}^{- 05} T_{on} + 1 {.71E}^{- 05} T_{off} - 1 {.4E}^{- 05} I + 3 {.95E}^{- 05} GV - {2E}^{- 07} T_{on}^{2} - 8 {.2E}^{- 07} T_{off}^{2} - 8 {.1E}^{- 06} I^{2} - {4E}^{- 07} {GV}^{2} - 5 {.1E}^{- 08} T_{on} T_{off} I + 4 {.14E}^{- 11} T_{on} IGV + 6 {.7E}^{- 08} T_{off} IGV - 2 {.2E}^{- 09} {IGVT}_{on}

[1] e-mail: sakthi.mech1990sss@gmail.com, mahendran200@gmail.com, jayasuthahar@gmail.com

Brasil

Brasil

An effect of nano-SiC with different dielectric mediums on AZ61/7.5% B₄C nanocomposites studied through electrical discharge machining and Taguchi based complex proportional assessment method

ABSTRACT

Brasil

Brasil

An effect of nano-SiC with different dielectric mediums on AZ61/7.5% B4C nanocomposites studied through electrical discharge machining and Taguchi based complex proportional assessment method

ABSTRACT

An effect of nano-SiC with different dielectric mediums on AZ61/7.5% B₄C nanocomposites studied through electrical discharge machining and Taguchi based complex proportional assessment method