Machinability analysis of rice husk ash and copper reinforced aluminium matrix composite

Talwinder Singh; Jatinder Kumar; Jujhar Singh

Machinability analysis of rice husk ash and copper reinforced aluminium matrix composite

Authors
Talwinder Singh, Jatinder Kumar, Jujhar Singh

Abstract
Recent developments in the manufacturing industry have fueled the demand for materials having higher strength, hardness and toughness. These materials pose a problem while machining with conventional machines available. The new materials available are lightweight combined with greater hardness and toughness. In this experimental work, rice husk ash and copper based aluminium matrix composite was fabricated using stir casting route. The machinability of the cast composite is analysed in form of material removal rate and overcut. During experimentation, Flushing Pressure, Peak Current, Pulse on Time, Pulse off Time, Wire Feed Rate, and Wire Tension were selected as input parameters and experiments were performed on wire-cut electric discharge machining. The scanning electron microscopy and energy dispersive spectroscopy was also performed on the composite casting. ANOVA result reveals that for maximum material removal rate, peak current is the most significant parameter, which contributes 64.61% followed by pulse on time (10.73%) and wire tension (10.64%), while other parameters are insignificant. for minimum overcut, the pulse on time is the most significant parameter which contributes 31% followed by flushing pressure (19.37%), peak current (18.82%) and pulse off time (13.84%).the other parameters are insignificant to achieve maximum dimensional accuracy. The nonlinear regression model for material removal rate and overcut are also presented, which reflects the dependency of the responses on the input variables.

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