ABSTRACT
The novel applications of MoSi2 and SiC as matrix and reinforcing materials in the creation of high-performance composites were investigated in this work. In particular, Spark Erosion Machining's geometric tolerances were studied in order to shed light on the technique's potential for precision manufacture in the realm of MoSi2-SiC composites. Our research focused on evaluating critical parameters and their impact on machining performance, including material removal rate, surface roughness, wear rate and drilled hole accuracy. In-depth research revealed the critical input factors that had the greatest impact on the machining procedure. Notably, parameters such as current (32%), sparking on time (23%), sparking gap voltage (12%), dielectric pressure (12%), and sparking off time (17%) emerged as the most influential factors, as determined by ANOVA analysis. These findings provide valuable insights into optimizing the Sparking EDM approach for MoSi2-SiC composite materials. This study further demonstrated the improvement in composite desirability ratings across multiple performance criteria, highlighting the effectiveness of Sparking EDM in enhancing machining outcomes (e.g., from 0.8523 to 0.9527). Correlations between the EDM's output responses were found to be quite high when geometric tolerances and the coefficient of determination (R2) were used (0.7858, 0.9625, 0.8427, 0.8678, 0.8474, 0.8368, 0.8344, 0.8671). Consider that, for the sake of a more complete understanding of the procedure's approach, the emphasis is on the methodology rather than the multifaceted metal removal mechanisms involved. This research doesn't dive further into the physical concerns of Spark Erosion Machining, but it does provide insights into the practical application of this technique in the precision manufacturing of MoSi2-SiC composite materials. For real-world medical applications such implanted devices, dental implants, surgical instruments, biological sensors and diagnostics, this study provides a valuable and encouraging approach. A validation experiment verifies the results, proving the feasibility of improved spark erosion in high-precision production. The results of this research show that EDM methods can be fine-tuned to produce ceramic composites with much greater MRR, superior surface finishes and a marked decrease in subsurface cracking and microstructural modifications. This is essential for protecting the integrity of materials used in life-saving medical equipment.
Subject(s)
CeramicsABSTRACT
Recently, researchers have been attempting to enhance the mechanical and tribological characteristics of thermosetting epoxy composites by incorporating inorganic nanoparticles and ensuring their uniform distribution throughout the matrix. This study characterises ball-milled ilmenite (FeTiO3-size of 63 nm) and silicon dioxide (SiO2-size of 67.5 nm) fillers added to epoxy in proportions of 0:0, 2.5:2.5, 5:5, and 7.5:7.5% by weight. A liquid ultrasonic technique is used to blend the fillers with the epoxy, and compression moulding is used to fabricate the composite. Mechanical tests were performed based on ASTM standards. Tensile strength, tensile modulus, flexural strength, flexural modulus and elongations at break(tensile and flexural test) of 5:5 wt % are 30.54%, 12.2%, 32.22%, 28.98%,23.78% and 23.53% higher than neat sample respectively. Shore "D" hardness and Izod's impact strength are 4.65% and 98.93% higher at 5:5 wt % than neat sample respectively. Specific wear rate decreased from 2.6 × 10-11 m3/Nm (neat GFRP: 0 wt % glass fibre reinforced polymer composite) to 0.7 × 10-11 m3/Nm at 5:5 wt % filler. Nanoparticles lowered the coefficient of friction by around 16.66%, 60.42%, and 33.33% at sliding distances of 100 m for 2.5:2.5, 5:5, and 7.5:7.5 wt % respectively with the neat sample. A 5:5 wt percent resulted in 76.68% less wear volume loss than pure GFRP. Field emission scanning electron microscopy (FESEM) analysis revealed element distributions, particle size, pullout of fibers, damaged interfaces, filler dispersion, voids, wear debris, interfacial debonding, and cavities. Thus, this approach enhances GFRP composite's mechanical, tribological, and structural properties.
Subject(s)
Epoxy Resins , Silicon Dioxide , Flexural StrengthABSTRACT
Research into rotary electrical discharge machining on high temperature with biomedical application Si3N4-TiN ceramic composite is presented in this paper. Current (I), pulse on time (Ton), pulse off time (Toff), dielectric pressure (DP), speed and spark gap voltage (Sv) are some of the many performance characteristics. Among the factors taken into account is the material removal rate, surface roughness, electrode wear rate, cylindricity, perpendicularity, top radial overcut, bottom radial over cut and run out. Multiple parameter combinations were validated experimentally and the resulting reactions were examined. Mean effects analysis and regression analysis are used to investigate the impacts of individual parameters. To comprehend the instantaneous behavior of the replies, multi-objective Jaya optimization is utilized to optimize the responses simultaneously. The multi-objective problem's outcomes are shown in 3D charts, with each showing the Pareto optimal solution. From this real conclusion, the optimal combinations of answers are extracted and reported. The aggregate optimization result was also shown, which factored in all eight responses. MRR of 0.238 g/min was obtained which is a 10.6% improvement from the experimental values. Electrode wear of 0.0028 g/min was obtained showing a 6.6% reduction. Similarly reduction in values of Surface roughness, top radial overcut and bottom radial over cut, Circularity, Perpendicularity, run out was observed and the percentages are 3.4, 4.7, 4.5, 7.8, 10.0 and 10.53 respectively. Details on the structural and morphological examinations of the various surface abnormalities that occur during the process have been presented.
