Investigations on electrical discharge machining parameters of silicon nitride particles reinforced magnesium composites

Sankar, Thulasi; Mohanavel, Vinayagam

doi:10.1590/1517-7076-RMAT-2024-0615

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Articles • Matéria (Rio J.) 29 (4) • 2024 • https://doi.org/10.1590/1517-7076-RMAT-2024-0615 linkcopy

Investigations on electrical discharge machining parameters of silicon nitride particles reinforced magnesium composites

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

The present research analysis the Electrical Discharge Machining parameters of reinforced magnesium composite. Through stir cast method, we synthesized the AZ61 magnesium alloy composite with varying weight percentages of silicon nitride (Si³N⁴) particles (0%, 4%, 8%, and 12%). This study fills a significant research gap in the Electrical Discharge Machining (EDM) machining of magnesium composites and optimizes parameters. The analysis involved machining the synthesized samples using the EDM process to calculate surface roughness (Ra) and Metal Removal Rate (MRR). Through advanced techniques such as analysis of variance (ANOVA) and L-16 design, we identified the optimal EDM machining parameters that led to superior machining surface quality and improved MRR. Based on ANOVA, the Pulse off time (Toff)/Pulse on time (Ton) and composites identified as 88%, 8%, and 2% influencing the MRR and 33%, 22% and 16% influences to the surface roughness of machined composite sample. The results help to clarify how particular parameter combinations affect machining results, allowing for more accurate control for enhanced performance.

Keywords:
AZ61; Electrical discharge machining; Metal removal rate; Silicon nitride; Stir casting; Surface roughness; Taguchi

Al	Zn	Fe	Ni	Mn	Si	Cu	Mg
6.51	1.09	0.004	0.001	0.22	0.04	0.003	Balance

COMPOSITE SAMPLE	B	NC1	NC2	NC3
Wt.% of AZ61 alloy	100	96	92	88
Wt.% of Si₃N₄ particles	0	4	8	12

SOURCE OR FACTOR	UNITS	LEVELS
SOURCE OR FACTOR	UNITS	1	2	3	4
Pulse off time (Toff)	(µs)	30	40	50	60
Pulse on time (Ton)	(µs)	90	100	110	120
Composite samples (C)	–	B	NC1	NC2	NC3

DESIGN	TOFF IN µs	TON IN µs	C	Ra IN µm	MRR IN mm³/min
D1	30	90	B	0.26	0.21
D2	30	100	NC1	0.39	0.2
D3	30	110	NC2	0.393	0.189
D4	30	120	NC3	0.45	0.12
D5	40	90	NC1	0.32	0.34
D6	40	100	B	0.3	0.32
D7	40	110	NC3	0.32	0.3
D8	40	120	NC2	0.35	0.28
D9	50	90	NC2	0.26	0.42
D10	50	100	NC3	0.34	0.43
D11	50	110	B	0.37	0.38
D12	50	120	NC1	0.42	0.42
D13	60	90	NC3	0.41	0.51
D14	60	100	NC2	0.3	0.54
D15	60	110	NC1	0.31	0.42
D16	60	120	B	0.32	0.45

DESIGN	TOFF IN µs	TON IN µs	C	Ra IN µm
D5	40	90	NC1	0.32
D7	40	110	NC3	0.32
D9	50	90	NC2	0.26
D11	50	110	B	0.37
D13	60	90	NC3	0.41
D15	60	110	NC1	0.31

DESIGN	TOFF IN µs	TON IN µs	C	MRR IN mm³/min
D1	30	90	B	0.21
D2	30	100	NC1	0.2
D3	30	110	NC2	0.189
D5	40	90	NC1	0.34
D6	40	100	B	0.32
D7	40	110	NC3	0.3
D9	50	90	NC2	0.42
D10	50	100	NC3	0.43
D11	50	110	B	0.38

DESIGN	TOFF IN µs	TON IN µs	C	Ra IN µm	MRR IN mm³/min
D5	40	90	NC1	0.32	0.34
D7	40	110	NC3	0.32	0.3
D9	50	90	NC2	0.26	0.42
D11	50	110	B	0.37	0.38

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Laboratório de Hidrogênio, Coppe - Universidade Federal do Rio de Janeiro, em cooperação com a Associação Brasileira do Hidrogênio, ABH2 Av. Moniz Aragão, 207, 21941-594, Rio de Janeiro, RJ, Brasil, Tel: +55 (21) 3938-8791 - Rio de Janeiro - RJ - Brazil
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