EDM Studies on Aluminum Alloy-Silicon Carbide Composites Developed by Vortex Technique and Pressure Die Casting

M. Kathiresan, T. Sornakumar

Department of Mechanical Engineering, Thiagarajar College of Engineering,Madurai-625015, India.

DOI: 10.4236/jmmce.2010.91007                

Abstract

Aluminum based metal matrix composites (MMCs) offer potential for advanced structural applications when high specific strength and modulus, as well as good elevated temperature resistance, are important. In the present work, aluminum alloy-silicon carbide composites were developed using a new combination of vortex method and pressure die casting technique. Electrical Discharge Machining (EDM) studies were conducted on the aluminum alloy-silicon carbide composite work piece using a copper electrode in an Electrical Discharge Machine. The Material Removal Rate (MRR) and surface roughness of the work piece increases with an increase in the current. The MRR decreases with increase in the percent weight of silicon carbide. The surface finish of the machined work piece improves with percent weight of silicon carbide.

Keywords

Aluminum Alloy, Silicon carbide, Die-casting, Electric Discharge Machining, Surface roughness.

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	Baki Karam?s, M., and Fehmi Nair., 2008, “Effects of reinforcement particle size in MMCs on extrusion die wear”, Wear, Vol.265, pp.1741–1750.
[2]	Allison, J.E., and Cole, G.S., 1993, “Metal matrix composite in the automotive industry: opportunities and challenges”, JOM, January 1993, pp.19–24.
[3]	Jose Duarte Marafona and Arlindo Araujo, 2009, “Influence of workpiece hardness on EDM performance”, Int. J. Mach. Tool. Manu., Vol.49, pp.744–748.
[4]	Karthikeyan, R., Lakshmi Narayanan, P.R., and Naagarazan, R.S., 1999, “Mathematical modelling for electric discharge machining of aluminium–silicon carbide particulate composites”, J. Mater. Process. Tech., Vol.87, pp.59–63.
[5]	Sushant Dhar, Rajesh Purohit, Nishant Saini, Akhil Sharma and Hemath Kumar, G., 2007, “Mathematical modeling of electric discharge machining of cast Al–4Cu–6Si alloy–10 wt.% SiCp composites”, J. Mater. Process. Tech., Vol.194, pp.24–29
[6]	Lloyd, D.J., 1994, “Particle reinforced aluminum and magnesium matrix composite.” Int. Mater. Rev., Vol. 39, pp.1–23.
[7]	Surappa, M.K., and Rohatgi, P.K., 1981, “Preparation and properties of aluminium alloy ceramic particle composites”, J. Mater. Sci., Vol.16 , pp.983–993
[8]	Surappa, M.K., 2003, “Aluminium matrix composites: Challenges and opportunities”, Sadhana, Vol.28, pp.319–334.
[9]	Sornakumar, T., and Senthilkumar, A., 2008, “Machinability of bronze–alumina composite with tungsten carbide cutting tool insert”, J. Mater. Process. Tech., Vol.202, pp.402–405.
[10]	Unigovski, Ya.B., and Gutman, E.M., 1999, “Surface morphology of a die-cast Mg alloy”, Appl. Surf. Sci., Vol.153, pp.47–52
[11]	Tsoukalas, V.D., 2008, “Optimization of porosity formation in AlSi9Cu9 pressure die castings using genetic algorithm analysis”, Mater. Design, Vol.29, pp.2027–2033.
[12]	Tharumarajah, A., 2008, “Benchmarking aluminium die casting operations”, Resour. Conserv. Recy., Vol.52, pp.1185–1189.