Optimization of electrical discharge machining process parameters for Al6061/cenosphere composite using grey-based hybrid approach  

采用基于灰度的混合方法优化Al6061/空心微珠复合材料电火花切割工艺参数（英文）

作　　者：A. DEY S. DEBNATH K. M. PANDEY 

机构地区：[1]Department of Mechanical Engineering, National Institute of Technology Silchar, Assam 788010, India [2]Department of Production Engineering, National Institute of Technology Agartala, Tripura 799055, India

出　　处：《Transactions of Nonferrous Metals Society of China》2017年第5期998-1010,共13页中国有色金属学报（英文版）

摘　　要：Fly ash has congregated considerable attention as a potential reinforcement for aluminum matrix composites(AMCs)to enhance selective properties and reduce the cost of fabrication.However,poor machinability of such AMCs limits their application.The present study focuses on the preparation of cenosphere fly ash reinforced Al6061alloys by compo casting method.X-ray diffraction analysis of the prepared AMCs exposes the presence of cenosphere particles without any formation of other intermetallic compounds.In this study,electrical discharge machining(EDM)was engaged to examine the machinability of the prepared metal matrix composite(MMCs).The measured performance characteristics for the various combinations of input process parameters were considered to be MRR,EWR and SR.Face centered central composite design(CCD)of response surface method(RSM)was employed to design the number of experimental trials required and a hybrid approach of grey-based response surface methodology(GRSM)was imposed for predicting the optimal combination of processing parameter in EDM process.Generous improvement was observed in the performance characteristics obtained by employing both the optimal setting of machining parameters.The optical3D surface profile graphs of the ED machined surface also revealed the improvement in surface quality and texture employing the optimal processing conditions proposed by hybrid GRSM approach.粉煤灰作为铝基复合材料的增强剂已得到越来越多的关注,其可以增强特定的性能,还可以减少制备成本。然而,铝基复合材料的加工性能较差限制了其发展。本研究采用复合铸造方法制备粉煤灰增强Al6061合金。X射线衍射分析表明铝基复合材料中只含有粉煤灰颗粒,不含其他金属间化合物。采用电火花切割评价所制备金属基复合材料的加工性能。采用不同的电火花切割工艺参数组合对材料去除率、电极磨损率、表面粗糙度等性能参数进行评价。采用响应曲面方法的中心复合设计对所需实验的数量进行优化,获得基于灰度的响应曲面方法,并用以预测电火花切割最佳工艺组合。采用基于灰度响应曲面方法预测得到的最佳工艺参数组合时,所得性能参数得到明显提高,电火花切割表面的3D轮廓图表明材料的表面质量和织构都得到提升。

关 键 词：compo casting electrical discharge machining response surface method grey-based response surface methodology analysis of variance desirability analysis 

分 类 号：TB333[一般工业技术—材料科学与工程] TG484[金属学及工艺—焊接]