Dr G. Ramanan currently working as an Associate professor in ACS College of Engineering at Bengaluru, India. I have received PhD in Aeronautical and Space Technology and M.E in Aerospace Technology from Madras Institute of Technology, Chennai and B.E. degree in Electronics and communication engineering from Anna university India. I have 12 years of Teaching experience and I have worked as an assistant professor in the Department of Aerospace Engineering, Noorul Islam centre for higher education for seven years. I have completed 2 sponsored projects and published 30 SCI Papers in reputed Journals. My research interest includes composites, Advanced manufacturing process, modelling and optimization of manufacturing process. Supervisors: Dr. J. Edwin Raja Dhas, NIT, Trichy, Dr. N. Murugan, PSG, Coimbatore, Dr. M. Kanthababu, Anna University, Chennai, and Prof.Chaman Lal Ojha, ISRO (Retd.), Trivandrum
This paper aims to establish the mechanical, corrosion and failure analysis using online acoustic... more This paper aims to establish the mechanical, corrosion and failure analysis using online acoustic emission of Al7075 alloy, Al7075-B4C composite and Al7075- B4C-Al2O3 hybrid composite with different Boron Carbide (B4C) content of 5, 10, 15 & 20 % and Nano Aluminium Oxide (Al2O3) content of 2% on a weight basis with the high energy stir casting method. The casted samples have been characterized by X-ray Diffraction (XRD), Thermo gravimetric analysis (TGA/DSC), Energy Dispersive Spectrum (EDS), and Scanning Electron Microscope (SEM). In case of hybrid composite, the hardness and the tensile strength decrease when the content of Al2O3 increases. However, in the present research, the addition of B4C with nano Al2O3 particles in certain proportions has increased the hardness and tensile strength. In addition, the tensile fractographs of the specimens were analysed using SEM. Acoustic Emission (AE) method was used for monitoring the acoustic energy that are released at the time of deformation process and early crack detection. The influence of the volume fraction of the B4C particulates on the microstructural and corrosion characteristics of Al7075- B4C with nano Al2O3 metal matrix composites (MMCs) was also studied. It has been observed from the literature that the direct strengthening of composites occurs due to the presence of hard ceramic phase, while the indirect strengthening arises from the thermal mismatch between the matrix alloy and reinforcing phase during solidification. Based on the database for material properties, the application area of HAMCs has been proposed in the present review. The effects of nanomaterial dispersion in the metal matrix and the formation of interfacial precipitates on these properties are also addressed. Particular attention is paid to the fundamentals and the structure–property relationships of such novel Nano composites.
Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope o... more Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope of assortment of interrelated complex pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an exertion on the machining execution material removal rate. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing ANN strategies. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was produced depending on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes demonstrates that the results of information; this shows the created neural system can be utilized as an option path for figuring response parameters for given process parameters. Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope of assortment of interrelated complex inputs are discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an exertion on the machining execution responses like surface roughness and. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing es. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes demonstrates that the results of the ANN are in great concurrence with the trial information; this shows the created neural system can be utilized as an option path for figuring response parameters for given process parameters. Wire cut discharge machining is a progressed machining strategy controlled by are discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will surface roughness and. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing es. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes the ANN are in great concurrence with the trial information; this shows the created neural system can be utilized as an option path for
The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite... more The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite was processed by down pouring stir casting technique. Invented metal matrix composites were subjected to hardness, tensile test, microstructure analysis, X-ray diffraction, energy dispersive spectrum, FT-IR analysis and thermal analysis. AA7075 metal matrix composites containing matrix and reinforcement. Microstructure suggests the relatively uniform distribution of carbon particles in matrix alloy. X-ray diffraction analysis and EDAX had been making sure the presence of activated carbon particles and its uniform distribution over the aluminium matrix. FTIR trace aging process, the simplest results have been got employing combo of complementary analytical strategies. Hardness and elongation test of AA7075-PAC composite enormously greater in comparison with basic AA7075 alloy and few helpful conclusions have been drawn.
Wire electric discharge machining (WEDM) has turned out to be one of the well-known machining pro... more Wire electric discharge machining (WEDM) has turned out to be one of the well-known machining procedures utilized in bringing up elaborate aspects on electrically conductive substances. To improve the performance of WEDM process an attempt was made to improve the material removal rate (MRR) and minimize surface roughness (SR) on AA7075-activated carbon composites. The machined surface integrity associated with MRR and SR have been analysed as a function of processing parameters, such as discharge current, pulse on time, pulse off time and servo speed rate. Analysis of variance (ANOVA) is carried out in the idea of identifying tremendous causes of parameters. Experimental outcome authorize the feasibility of proposed prediction strategy and the developed particle swarm optimization (PSO) algorithm. Experiment result indicates that the MRR and SR are more sensitive to a change in size than a change in volume fraction of reinforcement. AA7075-activated carbon composites have extensive applications in aerospace and marine sectors.
Wire cut discharge Machining is an advanced machining method controlled by a variety of interrela... more Wire cut discharge Machining is an advanced machining method controlled by a variety of interrelated complex parameters like discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an effect on the machining quality measures like surface roughness and material removal rate. In the present work Aluminium 7075 is used as matrix and activated charcoal with different percentage as reinforcement to fabricate metal matrix composites. The specimens are tested for Density, Hardness, Impact Strength and Ultimate tensile Strength. Best chosen samples are used to perform machining process in wire cut electrical discharge machine. 27 trials of experiments based on Response surface methodology are done and the observations are made. The quality of the machined samples is evaluated by the measurement of material removal rate and surface roughness. Results are utilized to develop the grey-fuzzy model. From this technique, the optimum combinations of process parameters are obtained and corresponding values of maximum material removal rate and minimum surface roughness are found out. From ANOVA analysis it is found that servo speed is the significant factor in determining the machining quality. Confirmatory experiments are performed to determine the effectiveness of the approach.
International Journal of Vehicle Structures & Systems , 2017
In automobile industries, usage of unconventional machining is increased due to their precision a... more In automobile industries, usage of unconventional machining is increased due to their precision and accuracy. This research work is planned to upgrade the Wire Electric Discharge Machining (WEDM) process parameters by considering the impact of discharge current, pulse on time, pulse off time and servo speed rate. Tests have been led with these parameters for the measurement of metal removal rate and surface roughness for each of the trial run. This information has been used to fit a quadratic numerical model. Predicted information has been used as a graphical representation for demonstrating the impact of the parameters on chose reactions. Predicted information given by the models has been utilized as a part of an ideal parametric mix to accomplish the unrealistic yield of the procedure. Response surface method with grey relational analysis has been utilized for enhancement. The ideal value has been checked to the predicted value from the confirmation tests.
The continuous introduction of new materials and the endless demands for engineers to produce com... more The continuous introduction of new materials and the endless demands for engineers to produce complicated shapes within tighter tolerances in many industrial applications are gradually increasing. From this point of view, machining special materials is present great importance and also the Electrical Discharge Machining (EDM) is a relatively modern machining process. In this study, a powerful tool to design optimization for quality is used to find the optimal parameters for machining operations. Process parameter optimization is essential for exploiting their potentials and capabilities to the fullest extent economically.An orthogonal array, the signal-to-noise ratio, and the analysis of variance are employed to investigate the cutting characteristics of alloys using tungsten carbide cutting tools. Through this study, not only can the optimal parameters for machining operations be obtained, but also the main machining parameters that affect the cutting performance in machining operations can be found. Here an optimization machining parameters of the Electrical Discharge Machining (EDM) process on aerospace alloys with multiple performance characteristics has been carried out.
The quality of machining of AA7075-PAC metal matrix composites by WEDM is investigated using resp... more The quality of machining of AA7075-PAC metal matrix composites by WEDM is investigated using response surface methodology and grey relative analysis. Method: Experimentation is designed and performed using Response surface methodology with 27 trials discharge current, pulse on time, pulse off time and servo speed rate as input variables. Material removal rate and surface roughness are measured as responses. Results are used to optimize the parameters using Grey relative analysis. Best combination of parameters was found by grey relative analysis. ANOVA technique is used to fi nd the infl uence of parameters on the responses. Findings: Grey relation analysis yields low surface roughness and high removal rate for the combination of Discharge current 17500A, pulse on time 5μs, pulse off time 50μs and servo speed 100 rpm. Confi rmation test increasing responses is performed and found to be good agreement with experimental results. Microstructure studies reveal the interfaces between the materials and the appearance of grain particles of the best combination parameters. Improvement: Results from Grey relative analysis slightly edge over the experimental results from Response surface technique.
This article illustrates the response surface methodology and artificial neural network primarily... more This article illustrates the response surface methodology and artificial neural network primarily based mathematical modelling for average machining parameters of powdered activated carbon and 7075 Al metal matrix composite throughout wire spark machining. Four WEDM parameters particularly Discharge current, pulse-on time, pulse-off time and servo speed were chosen as machining technique parameters. A back propagation neural network was developed to envision the maneuver model. The performance of the developed ANN models were connected with the RSM mathematical models of average machining parameters like material removal rate and surface roughness. The comparison clearly indicates that the ANN models offer much correct prediction compared to the RSM models. Combined impact of input methodology parameters on machining parameters shows that servo speed could be a heap of necessary parameter on input machining parameter than pulse-off time and discharge current. I. Introduction Wire discharge machining could also be a specialized thermal machining technique capable of accurately machining shapes of hard materials like aluminium, atomic number 22 etc. regarding region applications, MMCs presently have a tried price of accomplishment as thriving engineering materials as a result of the properties like high strength-to-weight quantitative relation, sensible wear resistance, and capability of operational almost temperatures [1]. Response surface methodology (RSM) can be a assortment of mathematical and applied math techniques for empirical model building. By careful sort of experiments, the target is to optimize a response of output variable that's influenced by several freelance variables of input variables associate experiment can be a series of tests in this changes unit of measurement created among the input variables therefore on spot the reasons for changes among the output response. The use of ancient machining processes to machine arduous composite materials causes serious tool wear attributable to abrasive nature of reinforcing particles thus shortening tool life [2]. Although, non-traditional machining techniques like water jet machining and beam machining(LBM) could also be used but the machining instrumentality pricey, height of the work piece could also be a constraint, and surface end obtained is not sensible [3], in line with Patiland Brahmankar throughout WEDM is correct and economical machining operation whereas not compromising machining performance is feasible. Motorcu and Sahin have machined the hardened AISI 1040 steel with triangular and sq. tools in varied machining conditions and sculptured the surface roughness statue maker has formulized experimental results of surface roughness and cutting forces by statistical procedure, and sculptural the implications of them in his study victimization S55C steel [4]. Effective and cost effective of work published on combined approach of ANN and RSM modelling of process parameters on the performance of during machining of PAC and 7075 Al MMCs. The most necessary performance live in WEDM is Material removal rate (MRR) and Surface Roughness (SR) intensive experimental work is therefore needed to analysis and optimize the strategy parameters to understand their impact on product quality. Response surface methodology (RSM) is one rising technique, that helps in ending the analysis of experiments with the littlest quantity experimental effort [5]. ANN approach is a good tool to predict process parameters; it will generate the outputs for a collection of inputs that area unit inside the vary of the initial inputs throughout the training part [6]. The current investigation aims at work the machining speed predictive models supported RSM and ANN throughout WEDM of PAC/7075 Al MMC. The models of average machining parameters were developed with the discharge current (IA), pulse-on time (TON), pulse-off time (TOFF) and servo speed (rpm) as the WEDM method parameters. The input-output information required to develop every RSM and ANN models area unit obtained through Box-Behnken style (BBD) of experiments.
Metal matrix composites (MMC) focuses primarily on high strength to weight ratio, corrosion resis... more Metal matrix composites (MMC) focuses primarily on high strength to weight ratio, corrosion resistance, high temperature resistance, machinability applications. The aim is to produce this metal matrix composites in a low cost to identify the specified requirements. Recently aluminium and its alloy reinforced with ceramic particle which demands good specific strength to weight ratio, better wear out. Al7075 metal reinforced with powdered activated carbon (PAC) has good potential. The fabrication process is carried out with a ratio of weight composition and a range of temperature deviations. In this experiment Al-PAC MMC with three different weight fractions of 3%, 6% and 9% were fabricated by mechanical stir casting method. The specimens of Al 7075-PAC MMC were tested for Ultimate tensile Strength, Density, Hardness and Impact Strength were investigated.
The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite... more The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite was processed by down pouring stir casting technique. Invented metal matrix composites were subjected to hardness, tensile test, microstructure analysis, X-ray diffraction, energy dispersive spectrum, FT-IR analysis and thermal analysis. AA7075 metal matrix composites containing matrix and reinforcement. Microstructure suggests the relatively uniform distribution of carbon particles in matrix alloy. X-ray diffraction analysis and EDAX had been making sure the presence of activated carbon particles and its uniform distribution over the aluminium matrix. FTIR trace aging process, the simplest results have been got employing combo of complementary analytical strategies. Hardness and elongation test of AA7075-PAC composite enormously greater in comparison with basic AA7075 alloy and few helpful conclusions have been drawn.
The present investigation aims to establish the mechanical and wear behavior of Aluminum 7075 (Al... more The present investigation aims to establish the mechanical and wear behavior of Aluminum 7075 (Al7075) reinforced with Boron Carbide (B4C) (28 µm particle size) and Graphene (Gr) nano Particle (100 nm particle size) composites. These composites were prepared by stir casting process and also based on 5, 10 and 15 weight percentages (wt. %) of B4C particles and 0.1, 0.2 and 0.3 wt.% of Gr. Al7075 is reinforced with B4C and Gr particles for production of MMC. The mechanical properties like tensile strength, hardness, flexural, impact test and also wear properties like coefficient of friction and wear rate were investigated. The test results revealed that the tensile strength, flexural strength and hardness increased with increasing the wt. % of B4C and Gr along with increase in toughness up to certain limits (10 % B4C). Wear rate noticed with Gr reinforced with Al7075-10%B4C composite is lower compared to other Al6061-10%B4C-Gr with various Wt. % composites. On comparison, the Al7075-10%B4C-0.2%Gr composite shows better wear rate compared to other composites. TGA/DTA analysis shows that increase in % of B4C and Gr 17% increased the ignition period of the composites. The coefficient of friction and the specific wear rate were obtained in terms of sliding distance at various loads in the range of 5 N, 10 N and15 N. It was found that when B4C content in composites increase, the wear resistance also increases monotonically with hardness. In addition, the hybridization of two reinforcements enhanced the wear resistance of composites, especially in case of high sliding speeds.
In this paper Al7075-TiC-MoS2 hybrid composites were prepared through stir-casting process and th... more In this paper Al7075-TiC-MoS2 hybrid composites were prepared through stir-casting process and their microstructure, mechanical and tribological properties are analyzed. Aluminium 7075 was selected as matrix and reinforced with harder TiC to improve the mechanical strength and softer MoS2 to enhance the resistance to wear. The prepared samples were tested for their hardness, microstructure, XRD analysis, tensile strength through acoustic emission and wear surface roughness behaviour. All prepared composites exhibited an improvement in hardness; tensile strength and wear resistance through acoustic emission were investigated. It was observed that reinforcement was uniformly distributed across the matrix material which was attributed through continuous stirring. The surface morphology analysed through micro structural analysis revealed that the reinforcement was uniformly distributed in the matrix. The wear resistance was significantly improved with the MoS2 addition which acted as a lubricant in-between the sliding surfaces. Thus it is concluded that the hybrid composites exhibits good tensile strength, hardness and wear resistance properties. An Acoustic emission system was employed in all the tests to monitor the acoustic energy release during the whole deformation process and some useful conclusions were drawn.
This paper aims to establish the mechanical, corrosion and failure analysis using online acoustic... more This paper aims to establish the mechanical, corrosion and failure analysis using online acoustic emission of Al7075 alloy, Al7075-B4C composite and Al7075- B4C-Al2O3 hybrid composite with different Boron Carbide (B4C) content of 5, 10, 15 & 20 % and Nano Aluminium Oxide (Al2O3) content of 2% on a weight basis with the high energy stir casting method. The casted samples have been characterized by X-ray Diffraction (XRD), Thermo gravimetric analysis (TGA/DSC), Energy Dispersive Spectrum (EDS), and Scanning Electron Microscope (SEM). In case of hybrid composite, the hardness and the tensile strength decrease when the content of Al2O3 increases. However, in the present research, the addition of B4C with nano Al2O3 particles in certain proportions has increased the hardness and tensile strength. In addition, the tensile fractographs of the specimens were analysed using SEM. Acoustic Emission (AE) method was used for monitoring the acoustic energy that are released at the time of deformation process and early crack detection. The influence of the volume fraction of the B4C particulates on the microstructural and corrosion characteristics of Al7075- B4C with nano Al2O3 metal matrix composites (MMCs) was also studied. It has been observed from the literature that the direct strengthening of composites occurs due to the presence of hard ceramic phase, while the indirect strengthening arises from the thermal mismatch between the matrix alloy and reinforcing phase during solidification. Based on the database for material properties, the application area of HAMCs has been proposed in the present review. The effects of nanomaterial dispersion in the metal matrix and the formation of interfacial precipitates on these properties are also addressed. Particular attention is paid to the fundamentals and the structure–property relationships of such novel Nano composites.
Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope o... more Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope of assortment of interrelated complex pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an exertion on the machining execution material removal rate. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing ANN strategies. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was produced depending on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes demonstrates that the results of information; this shows the created neural system can be utilized as an option path for figuring response parameters for given process parameters. Wire cut discharge machining is a progressed machining strategy controlled by an outsized scope of assortment of interrelated complex inputs are discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an exertion on the machining execution responses like surface roughness and. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing es. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes demonstrates that the results of the ANN are in great concurrence with the trial information; this shows the created neural system can be utilized as an option path for figuring response parameters for given process parameters. Wire cut discharge machining is a progressed machining strategy controlled by are discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will surface roughness and. This paper presents a consistent way to deal with optimize Wire EDM response parameters for the aluminum metal matrix composites utilizing es. In the present work aluminum 7075 is utilized as matrix and activated carbon as reinforcement metal matrix composites. 27 trails of investigations in light of response surface procedure are done and the perceptions are made. ANN was on back propagation for expectation of the numerous reactions. The ANN was consequently prepared with test information. Testing of the ANN is done utilizing exploratory information not utilized amid preparing. The outcomes the ANN are in great concurrence with the trial information; this shows the created neural system can be utilized as an option path for
The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite... more The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite was processed by down pouring stir casting technique. Invented metal matrix composites were subjected to hardness, tensile test, microstructure analysis, X-ray diffraction, energy dispersive spectrum, FT-IR analysis and thermal analysis. AA7075 metal matrix composites containing matrix and reinforcement. Microstructure suggests the relatively uniform distribution of carbon particles in matrix alloy. X-ray diffraction analysis and EDAX had been making sure the presence of activated carbon particles and its uniform distribution over the aluminium matrix. FTIR trace aging process, the simplest results have been got employing combo of complementary analytical strategies. Hardness and elongation test of AA7075-PAC composite enormously greater in comparison with basic AA7075 alloy and few helpful conclusions have been drawn.
Wire electric discharge machining (WEDM) has turned out to be one of the well-known machining pro... more Wire electric discharge machining (WEDM) has turned out to be one of the well-known machining procedures utilized in bringing up elaborate aspects on electrically conductive substances. To improve the performance of WEDM process an attempt was made to improve the material removal rate (MRR) and minimize surface roughness (SR) on AA7075-activated carbon composites. The machined surface integrity associated with MRR and SR have been analysed as a function of processing parameters, such as discharge current, pulse on time, pulse off time and servo speed rate. Analysis of variance (ANOVA) is carried out in the idea of identifying tremendous causes of parameters. Experimental outcome authorize the feasibility of proposed prediction strategy and the developed particle swarm optimization (PSO) algorithm. Experiment result indicates that the MRR and SR are more sensitive to a change in size than a change in volume fraction of reinforcement. AA7075-activated carbon composites have extensive applications in aerospace and marine sectors.
Wire cut discharge Machining is an advanced machining method controlled by a variety of interrela... more Wire cut discharge Machining is an advanced machining method controlled by a variety of interrelated complex parameters like discharge current, pulse on time, pulse off time and servo speed rate. Any slight variations in one will have an effect on the machining quality measures like surface roughness and material removal rate. In the present work Aluminium 7075 is used as matrix and activated charcoal with different percentage as reinforcement to fabricate metal matrix composites. The specimens are tested for Density, Hardness, Impact Strength and Ultimate tensile Strength. Best chosen samples are used to perform machining process in wire cut electrical discharge machine. 27 trials of experiments based on Response surface methodology are done and the observations are made. The quality of the machined samples is evaluated by the measurement of material removal rate and surface roughness. Results are utilized to develop the grey-fuzzy model. From this technique, the optimum combinations of process parameters are obtained and corresponding values of maximum material removal rate and minimum surface roughness are found out. From ANOVA analysis it is found that servo speed is the significant factor in determining the machining quality. Confirmatory experiments are performed to determine the effectiveness of the approach.
International Journal of Vehicle Structures & Systems , 2017
In automobile industries, usage of unconventional machining is increased due to their precision a... more In automobile industries, usage of unconventional machining is increased due to their precision and accuracy. This research work is planned to upgrade the Wire Electric Discharge Machining (WEDM) process parameters by considering the impact of discharge current, pulse on time, pulse off time and servo speed rate. Tests have been led with these parameters for the measurement of metal removal rate and surface roughness for each of the trial run. This information has been used to fit a quadratic numerical model. Predicted information has been used as a graphical representation for demonstrating the impact of the parameters on chose reactions. Predicted information given by the models has been utilized as a part of an ideal parametric mix to accomplish the unrealistic yield of the procedure. Response surface method with grey relational analysis has been utilized for enhancement. The ideal value has been checked to the predicted value from the confirmation tests.
The continuous introduction of new materials and the endless demands for engineers to produce com... more The continuous introduction of new materials and the endless demands for engineers to produce complicated shapes within tighter tolerances in many industrial applications are gradually increasing. From this point of view, machining special materials is present great importance and also the Electrical Discharge Machining (EDM) is a relatively modern machining process. In this study, a powerful tool to design optimization for quality is used to find the optimal parameters for machining operations. Process parameter optimization is essential for exploiting their potentials and capabilities to the fullest extent economically.An orthogonal array, the signal-to-noise ratio, and the analysis of variance are employed to investigate the cutting characteristics of alloys using tungsten carbide cutting tools. Through this study, not only can the optimal parameters for machining operations be obtained, but also the main machining parameters that affect the cutting performance in machining operations can be found. Here an optimization machining parameters of the Electrical Discharge Machining (EDM) process on aerospace alloys with multiple performance characteristics has been carried out.
The quality of machining of AA7075-PAC metal matrix composites by WEDM is investigated using resp... more The quality of machining of AA7075-PAC metal matrix composites by WEDM is investigated using response surface methodology and grey relative analysis. Method: Experimentation is designed and performed using Response surface methodology with 27 trials discharge current, pulse on time, pulse off time and servo speed rate as input variables. Material removal rate and surface roughness are measured as responses. Results are used to optimize the parameters using Grey relative analysis. Best combination of parameters was found by grey relative analysis. ANOVA technique is used to fi nd the infl uence of parameters on the responses. Findings: Grey relation analysis yields low surface roughness and high removal rate for the combination of Discharge current 17500A, pulse on time 5μs, pulse off time 50μs and servo speed 100 rpm. Confi rmation test increasing responses is performed and found to be good agreement with experimental results. Microstructure studies reveal the interfaces between the materials and the appearance of grain particles of the best combination parameters. Improvement: Results from Grey relative analysis slightly edge over the experimental results from Response surface technique.
This article illustrates the response surface methodology and artificial neural network primarily... more This article illustrates the response surface methodology and artificial neural network primarily based mathematical modelling for average machining parameters of powdered activated carbon and 7075 Al metal matrix composite throughout wire spark machining. Four WEDM parameters particularly Discharge current, pulse-on time, pulse-off time and servo speed were chosen as machining technique parameters. A back propagation neural network was developed to envision the maneuver model. The performance of the developed ANN models were connected with the RSM mathematical models of average machining parameters like material removal rate and surface roughness. The comparison clearly indicates that the ANN models offer much correct prediction compared to the RSM models. Combined impact of input methodology parameters on machining parameters shows that servo speed could be a heap of necessary parameter on input machining parameter than pulse-off time and discharge current. I. Introduction Wire discharge machining could also be a specialized thermal machining technique capable of accurately machining shapes of hard materials like aluminium, atomic number 22 etc. regarding region applications, MMCs presently have a tried price of accomplishment as thriving engineering materials as a result of the properties like high strength-to-weight quantitative relation, sensible wear resistance, and capability of operational almost temperatures [1]. Response surface methodology (RSM) can be a assortment of mathematical and applied math techniques for empirical model building. By careful sort of experiments, the target is to optimize a response of output variable that's influenced by several freelance variables of input variables associate experiment can be a series of tests in this changes unit of measurement created among the input variables therefore on spot the reasons for changes among the output response. The use of ancient machining processes to machine arduous composite materials causes serious tool wear attributable to abrasive nature of reinforcing particles thus shortening tool life [2]. Although, non-traditional machining techniques like water jet machining and beam machining(LBM) could also be used but the machining instrumentality pricey, height of the work piece could also be a constraint, and surface end obtained is not sensible [3], in line with Patiland Brahmankar throughout WEDM is correct and economical machining operation whereas not compromising machining performance is feasible. Motorcu and Sahin have machined the hardened AISI 1040 steel with triangular and sq. tools in varied machining conditions and sculptured the surface roughness statue maker has formulized experimental results of surface roughness and cutting forces by statistical procedure, and sculptural the implications of them in his study victimization S55C steel [4]. Effective and cost effective of work published on combined approach of ANN and RSM modelling of process parameters on the performance of during machining of PAC and 7075 Al MMCs. The most necessary performance live in WEDM is Material removal rate (MRR) and Surface Roughness (SR) intensive experimental work is therefore needed to analysis and optimize the strategy parameters to understand their impact on product quality. Response surface methodology (RSM) is one rising technique, that helps in ending the analysis of experiments with the littlest quantity experimental effort [5]. ANN approach is a good tool to predict process parameters; it will generate the outputs for a collection of inputs that area unit inside the vary of the initial inputs throughout the training part [6]. The current investigation aims at work the machining speed predictive models supported RSM and ANN throughout WEDM of PAC/7075 Al MMC. The models of average machining parameters were developed with the discharge current (IA), pulse-on time (TON), pulse-off time (TOFF) and servo speed (rpm) as the WEDM method parameters. The input-output information required to develop every RSM and ANN models area unit obtained through Box-Behnken style (BBD) of experiments.
Metal matrix composites (MMC) focuses primarily on high strength to weight ratio, corrosion resis... more Metal matrix composites (MMC) focuses primarily on high strength to weight ratio, corrosion resistance, high temperature resistance, machinability applications. The aim is to produce this metal matrix composites in a low cost to identify the specified requirements. Recently aluminium and its alloy reinforced with ceramic particle which demands good specific strength to weight ratio, better wear out. Al7075 metal reinforced with powdered activated carbon (PAC) has good potential. The fabrication process is carried out with a ratio of weight composition and a range of temperature deviations. In this experiment Al-PAC MMC with three different weight fractions of 3%, 6% and 9% were fabricated by mechanical stir casting method. The specimens of Al 7075-PAC MMC were tested for Ultimate tensile Strength, Density, Hardness and Impact Strength were investigated.
The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite... more The present work represents the AA7075 and Powdered Activated Carbon (PAC) metal matrix composite was processed by down pouring stir casting technique. Invented metal matrix composites were subjected to hardness, tensile test, microstructure analysis, X-ray diffraction, energy dispersive spectrum, FT-IR analysis and thermal analysis. AA7075 metal matrix composites containing matrix and reinforcement. Microstructure suggests the relatively uniform distribution of carbon particles in matrix alloy. X-ray diffraction analysis and EDAX had been making sure the presence of activated carbon particles and its uniform distribution over the aluminium matrix. FTIR trace aging process, the simplest results have been got employing combo of complementary analytical strategies. Hardness and elongation test of AA7075-PAC composite enormously greater in comparison with basic AA7075 alloy and few helpful conclusions have been drawn.
The present investigation aims to establish the mechanical and wear behavior of Aluminum 7075 (Al... more The present investigation aims to establish the mechanical and wear behavior of Aluminum 7075 (Al7075) reinforced with Boron Carbide (B4C) (28 µm particle size) and Graphene (Gr) nano Particle (100 nm particle size) composites. These composites were prepared by stir casting process and also based on 5, 10 and 15 weight percentages (wt. %) of B4C particles and 0.1, 0.2 and 0.3 wt.% of Gr. Al7075 is reinforced with B4C and Gr particles for production of MMC. The mechanical properties like tensile strength, hardness, flexural, impact test and also wear properties like coefficient of friction and wear rate were investigated. The test results revealed that the tensile strength, flexural strength and hardness increased with increasing the wt. % of B4C and Gr along with increase in toughness up to certain limits (10 % B4C). Wear rate noticed with Gr reinforced with Al7075-10%B4C composite is lower compared to other Al6061-10%B4C-Gr with various Wt. % composites. On comparison, the Al7075-10%B4C-0.2%Gr composite shows better wear rate compared to other composites. TGA/DTA analysis shows that increase in % of B4C and Gr 17% increased the ignition period of the composites. The coefficient of friction and the specific wear rate were obtained in terms of sliding distance at various loads in the range of 5 N, 10 N and15 N. It was found that when B4C content in composites increase, the wear resistance also increases monotonically with hardness. In addition, the hybridization of two reinforcements enhanced the wear resistance of composites, especially in case of high sliding speeds.
In this paper Al7075-TiC-MoS2 hybrid composites were prepared through stir-casting process and th... more In this paper Al7075-TiC-MoS2 hybrid composites were prepared through stir-casting process and their microstructure, mechanical and tribological properties are analyzed. Aluminium 7075 was selected as matrix and reinforced with harder TiC to improve the mechanical strength and softer MoS2 to enhance the resistance to wear. The prepared samples were tested for their hardness, microstructure, XRD analysis, tensile strength through acoustic emission and wear surface roughness behaviour. All prepared composites exhibited an improvement in hardness; tensile strength and wear resistance through acoustic emission were investigated. It was observed that reinforcement was uniformly distributed across the matrix material which was attributed through continuous stirring. The surface morphology analysed through micro structural analysis revealed that the reinforcement was uniformly distributed in the matrix. The wear resistance was significantly improved with the MoS2 addition which acted as a lubricant in-between the sliding surfaces. Thus it is concluded that the hybrid composites exhibits good tensile strength, hardness and wear resistance properties. An Acoustic emission system was employed in all the tests to monitor the acoustic energy release during the whole deformation process and some useful conclusions were drawn.
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