Experimental Investigation on Super Alloys using Al7178 Metal Matrix Tools (Aluminum Oxide Materials of Different Weight Percentages 3%, 6%, 9%, 12%) on Electrical Discharge Machining
Abstract
The primary nonferrous metals consist of aluminum, copper, lead, nickel, chromium, manganese, magnesium, titanium, zinc, and alloys like brass. These metals are typically extracted from minerals such as sulfides, carbonates, and silicates. The addition of alloying elements enhances their properties when added in appropriate quantities. Non -ferrous metals are widely utilized due to their favorable characteristics, such as lightweight (e.g. aluminum), high electrical conductivity (e.g. copper), non-magnetism, and corrosion resistance (e.g. zinc). One of the most significant nonferrous alloys is the Al 7178 series alloy, which is commonly used in technical applications. EDM is a method for controlled removal of metal that uses electrical discharge. This process uses an electric spark to erode the workpiece and shape the finished part. Metal removal is accomplished by applying a pulsed charge (ON/OFF) to the workpiece through an electrode using a high -frequency current. The workpiece is subjected to controlled erosion, resulting in the removal of tiny metal fragments. Typically, electrodes made of copper, graphite, and brass are utilized in EDM. The current project investigates the use of the metal matrix material Al7 178 (Al2O3-reinforced Al7178) as a tool/electrode for machining the superalloy Superni 90. In this study, aluminum alloy 7178 is utilized as the base metal, Al2O3 is chosen as the reinforcement material, weight fraction 3%, 6%, 9%, 12% as the tool material, and nickel-based alloy as the workpiece being studied. Superni90 has been selected. Material removal rate, surface roughness and tool wear rate in electrical machining discharge. Regression models were developed for MRR and TWR based on experimental data. The Mitutoyo surface roughness measuring machine is utilized to measure the surface roughness of the processed workpiece. The geometric accuracy of the surfaces created on the workpiece is evaluated using MATLab software .
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Introduction
Modern technology has led to an explosion of lightweight materials, particularly in the realms of aerospace and automobile. The research on newhigh-strength aluminum alloysis being undertaken by numerous countries and corporations, The aim is to decrease It is crucial to minimize the weight of the materials as much as possible, while still maintaining the stability of mechanics and corrosion resistance for the overall structure, in order to substitute traditional materials such as iron. Nume rous modern materials utilized in space exploration, weaponry, and nuclear industries have been produced in the past few years. Due to their increased hardness, toughness, strength, and resistance to heat and wear, these materials cannot be processed using conventional machining methods. The emergence of New Machining Procedures, or Unconventional Machining Procedures, is a direct outcome of the advancement of innovative metal removal techniques. These procedures enable the fabrication of intricate and sophisticated shapes on the workpiece, regardless of the material's strength, hardness, toughness, or brittleness.
Conclusion
From the experimental data and results obtained from theanalysis the following conclusions may be drawn.
From the experimentation Al2O3 3% is found to be the optimum solution from all the cases (Al2O3 3%, Al2O3 6%, Al2O3 9% & Al2O3 12%)
• For 3% Al2O3, the Material Removal Rate is high (3.45 mm3/min), Surface Roughness is less in Trail 1which is 3.955μm. Hence, the optimum condition for 3% Al2O3 is in Trail 1 (Parameters: current 4amps, pulse on time 100μs, pulse off time 50μs, voltage 30volts).
• The optimized condition for lower Roughness, lower TWR, lower Geometrical error and higher MRR is in Trail 5 (Parameters: current 8amps, pulse on time 450μs, pulse off time 75μs, voltage 45volts).
• The main input parameter influencing the responsesis current and its optimum value is 8amps.