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MACHINABILITY OF ALUMINIUM METAL MATRIX COMPOSITE REINFORCED WITH ALUMINA USING ELECTRO-DISCHARGE MACHINING

NANIMINA, ALEXIS MOUANGUE NANIMINA (2010) MACHINABILITY OF ALUMINIUM METAL MATRIX COMPOSITE REINFORCED WITH ALUMINA USING ELECTRO-DISCHARGE MACHINING. Masters thesis, UNIVERSITI TEKNOLOGI PETRONAS.

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Abstract

Aluminium metal matrix composites (AMMCs) are making inroads in various engineering applications (aviation, marine, automotive parts as diesel engine pistons, cylinder, and brake components) requiring higher strength and stiffness than those offered by conventional aluminium alloys. Traditional machining of AMMCs however is difficult due to hard reinforcement in the AMMC material which tends to wrap around the cutting tool-bit leading to tool breakage. Electro-discharge machining (EDM) has been successfully applied on standard aluminium alloys such as Al 6061 but yet to be tested on 30% Al2O3 reinforced AMMC. In this study, a specific machining performance on 30% Al2O3 reinforced AMMC is assessed in comparison with Al 6061. The characteristics analyzed are surface roughness (Ra), material removal rate (MRR), tool wear ratio (TWR), overcut (OC) and surface morphology. Process parameters used, are peak current, ON-time (pulse duration) and OFF-time (pause duration), were varied in this research to determine the machinability of AMMC reinforced by 30% Al2O3 by using EDM. The research methodology adopted was using design of experiment (DOE) and results from the experiment were analyzed and interpreted. The response surface methodology (RSM) was used to predict the machining performance and empirical mathematical models for Ra, MRR and TWR using Design Expert software. Results showed that peak current, ON-time and OFF-time have influenced on the EDM performance. Machinability of electro-discharge machining of 30% Al2O3 reinforced AMMC composite using electrolytic copper electrode has been proven feasible at certain parameters setting. Nevertheless, EDM machining performance of Al 6061 is better than that of AMMC. For machining at a specific material removal rate, minimal surface roughness, and low overcut can be obtained at low peak current or short ONtime and longer OFF-time however tool wear ratio remains high. Appropriate setting of EDM parameters that results in optimum machining performance have been identified in this research.

Item Type: Thesis (Masters)
Subject: UNSPECIFIED
Divisions: Engineering > Mechanical
Depositing User: Users 5 not found.
Date Deposited: 05 Jun 2012 08:30
Last Modified: 25 Jan 2017 09:43
URI: http://utpedia.utp.edu.my/id/eprint/2878

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