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Performance Monitoring of WEDM Using Online Acoustic Emission Technique

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Abstract

This study reveals the machining of Aluminium (Al) based hybrid Metal Matrix Composite (MMC) consists of Silicon Carbide (SiC) and Boron Carbide (B4C) as the reinforcements prepared through stir casting route. The composite is subjected to machining through Wire Electrical Discharge Machining (WEDM). The Acoustic Emission (AE) technique is incorporated to monitor the machining process through online. The WEDM cutting has been carried out at different feed rates (2.25, 3 and 3.75 mm/min) and AE signals generated during the machining are recorded using a 150 kHz resonant sensor along with the 40 dB pre-amplification and also band pass filter (100-400 kHz). The variation of AE counts, AE energy and amplitude with the respect to machining time for different feed rates are discussed in detail. The result shows that the generation of AE signals is not uniform and varies with time and feed rates. Sudden variation of AE counts, energy and amplitude during machining of the MMC shows crossing of cutting wire through different phases of work piece.

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Acknowledgements

The authors express their thanks to DAE - BRNS, Mumbai, for providing the financial support to carry out this work vide project no. 2012/34/39/BRNS.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Kalasalingam University, Krishnankoil, 626126, India

    S. Suresh Kumar, M. Uthayakumar & S. Thirumalai Kumaran

  2. Physical Metallurgy Group, Indira Gandhi Center for Atomic Research, Kalpakkam, 603102, India

    P. Parameswaran

  3. Metallurgy and Materials Group, Indira Gandhi Center for Atomic Research, Kalpakkam, 603102, India

    T. K. Haneef, C. K. Mukhopadhyay & B. P. C. Rao

Authors
  1. S. Suresh Kumar
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  2. M. Uthayakumar
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  3. S. Thirumalai Kumaran
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  4. P. Parameswaran
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  5. T. K. Haneef
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  6. C. K. Mukhopadhyay
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  7. B. P. C. Rao
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Correspondence to M. Uthayakumar.

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Kumar, S.S., Uthayakumar, M., Kumaran, S.T. et al. Performance Monitoring of WEDM Using Online Acoustic Emission Technique. Silicon 10, 2635–2642 (2018). https://doi.org/10.1007/s12633-018-9800-9

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  • DOI: https://doi.org/10.1007/s12633-018-9800-9

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