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Performance Monitoring of WEDM Using Online Acoustic Emission Technique

  • S. Suresh Kumar
  • M. Uthayakumar
  • S. Thirumalai Kumaran
  • P. Parameswaran
  • T. K. Haneef
  • C. K. Mukhopadhyay
  • B. P. C. Rao
Original Paper


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.


Composite WEDM Acoustic emission 


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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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Copyright information

© Springer Science+Business Media B.V., part of Springer Nature 2018

Authors and Affiliations

  • S. Suresh Kumar
    • 1
  • M. Uthayakumar
    • 1
  • S. Thirumalai Kumaran
    • 1
  • P. Parameswaran
    • 2
  • T. K. Haneef
    • 3
  • C. K. Mukhopadhyay
    • 3
  • B. P. C. Rao
    • 3
  1. 1.Faculty of Mechanical EngineeringKalasalingam UniversityKrishnankoilIndia
  2. 2.Physical Metallurgy GroupIndira Gandhi Center for Atomic ResearchKalpakkamIndia
  3. 3.Metallurgy and Materials GroupIndira Gandhi Center for Atomic ResearchKalpakkamIndia

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