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Keywords

Electrochemical Discharge Machining, Hybrid composite machining, Aluminum 6061, Silicon Carbide, Boron carbide

Document Type

Research Paper

Abstract

This study investigates the machining performance of the Electrochemical Discharge Machining (ECDM) process on a hybrid composite material comprising Aluminum 6061 reinforced with 6% silicon carbide (SiC) and 6% boron carbide (B4C). Experiments evaluated the effects of electrolyte concentration, voltage, pulse-on time, and pulse-off time on Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Taguchi analysis and ANOVA highlighted the significant influence of these parameters on machining outcomes. The optimal MRR (0.113 g/min) was achieved at 20% electrolyte concentration, 40V, 150 µs pulse-on time, and 25 µs pulse-off time. The best TWR (0.007 g/min) occurred at 30% concentration, 30V, 150 µs pulse-on time, and 50 µs pulse-off time. The optimal SR (4.757 µm) was observed at 20% concentration, 30V, 100 µs pulse-on time, and 75 µs pulse-off time. The findings emphasize the importance of parameter optimization in improving machining efficiency and surface integrity, offering valuable insights for hybrid composite applications. In particular, the study reveals that higher electrolyte concentrations and voltages generally enhance MRR but can increase TWR and degrade SR. These findings underline the importance of parameter optimization for balancing productivity and surface integrity. This research provides valuable insights for industries seeking precise and efficient machining of hybrid composites, showcasing a 34% enhancement in machining efficiency and a 21% improvement in surface quality using the optimized ECDM conditions.

References

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Highlights

ECDM for Al6061-SiC-B4C composites was optimized using Taguchi analysis and ANOVA to enhance machining performance. 34% efficiency, 21% surface quality improvement at 20% electrolyte, 40V, 150µs Pon. MRR and SR were improved, benefiting machining applications in aerospace, automotive, and defense industries.

DOI

10.30684/etj.2025.156592.1881

First Page

444

Last Page

458

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