Experimental Investigation for Performance Study of Wire Electrochemical Spark Cutting of Silica Epoxy Nanocomposites

Abstract

Purpose

Polymer Nanocomposites are advanced engineering composites with enhanced properties. These materials play a central role in various industrial sectors. The growing awareness of the key parameters (which influence the physical properties) with different combination of matrix-reinforcement, are making them more attractive in various applications. Machining of these materials is a challenging task for engineers with their properties (hardness and brittleness) due to various combinations of matrix-reinforcement. Therefore, the aim of present work is to investigate the machining behaviour of Silicon Dioxide (silica) Epoxy Nanocomposite due to straight cutting by using Wire Electrochemical Spark Cutting (WECSC) process.

Method

A specific number of experiments were conducted based on one parameter at-a-time approach to study the effect of influencing input parameters.

Result

The effect of various process parameters namely voltage supply, electrolyte concentration, wire velocity, pulse-on time and silica particle concentration (Cp) such as 3%, 4% and 5% (weight percent) on performance measures such as material removal rate (MRR) and surface roughness were demonstrated experimentally.

Conclusion

WECSC has been found effective technique for cutting of Silicon Dioxide Epoxy Nanocomposite. It is reported that MRR increases with decrease in silica particle concentration in Silicon Dioxide Epoxy Nanocomposite.

This is a preview of subscription content, log in to check access.

References

  1. 1.

    Sprenger S (2013) Epoxy resin composites with surface modified silicon dioxide nanoparticles: a review. J Appl Polym Sci 130(3):1421–1428

    CAS  Article  Google Scholar 

  2. 2.

    Jumahat A, Soutis C, Abdullah SA, Kasolang S (2012) Tensile properties of nanosilica/epoxy nanocomposites. Procedia Engineering 41:1634–1640

    CAS  Article  Google Scholar 

  3. 3.

    Singh SK, Kumar A. and Jain A, (2018) Improving tensile and flexural properties of SiO2-epoxy polymer nanocomposite. Materials Today: Proceedings 5(2):6339–6344

  4. 4.

    Gong Y, Baik YJ, Li CP, Byon C, Park JM, Ko TJ (2017) Experimental and modeling investigation on machined surfaces of HDPE-MWCNT polymer nanocomposite. Int J Adv Manuf Technol 88(1–4):879–885

    Article  Google Scholar 

  5. 5.

    Starost K, and Njuguna J, (2014) A review on the effect of mechanical drilling on polymer nanocomposites. In IOP Conference Series: Materials Science and Engineering (Vol. 64, No. 1, p. 012031). IOP Publishing

  6. 6.

    Abrate S, Walton D (1992) Machining of composite materials. Part II: non-traditional methods. Compos Manuf 3(2):85–94

    Article  Google Scholar 

  7. 7.

    Jain VK, Rao PS, Choudhury SK, Rajurkar KP (1991) Experimental investigations into traveling wire electro-chemical spark machining (TW-ECSM) of composites. J Eng Ind 113:75–84

    Article  Google Scholar 

  8. 8.

    Yadav P, Yadava V, Narayan A (2018) Experimental investigation of kerf characteristics through wire electrochemical spark cutting of alumina epoxy nanocomposite. J Mech Sci Technol 32(1):345–350

    Article  Google Scholar 

  9. 9.

    Bhuyan BK, Yadava V (2013) Experimental modeling and multi-objective optimization of traveling wire electrochemical spark machining (TW-ECSM) process. J Mech Sci Technol 27(8):2467–2476

    Article  Google Scholar 

  10. 10.

    Malik A, and Manna A, (2017) Travelling wire electrochemical spark machining: an overview. In: Non-traditional micromachining processes, Springer, Cham, 393–411

  11. 11.

    Jain VK, Priyadarshini D (2014) Fabrication of microchannels in ceramics (quartz) using electrochemical spark micromachining (ECSMM). J Adv Manuf Syst 13(1):5–16. https://doi.org/10.1142/S0219686714500012

  12. 12.

    Nesarikar VV, Jain VK, Choudhury SK (1994) Traveling wire electro-chemical spark machining of thick sheets of Kevlar-epoxy composites. Proceedings of the sixteenth AIMTDR conference 672–677

  13. 13.

    Peng WY, Liao YS (2004) Study of electrochemical discharge machining technology for slicing non-conductive brittle materials. J Mater Process Technol 149(1–3):363–369

    CAS  Article  Google Scholar 

  14. 14.

    Kuo KY, Wu KL, Yang CK, Yan BH (2013) Wire electrochemical discharge machining (WECDM) of quartz glass with titrated electrolyte flow. Int J Mach Tools Manuf 72:50–57

    Article  Google Scholar 

  15. 15.

    Bhuyan BK, Yadava V (2014) Experimental study of traveling wire electrochemical spark machining of borosilicate glass. Mater Manuf Process 29:298–304

    CAS  Article  Google Scholar 

  16. 16.

    Singh YP, Jain VK, Kumar P, Agrawal DC (1996) Machining piezoelectric (PZT) ceramics using an electro-chemical spark machining (ECSM) process. J Mater Process Technol 58(1):24–31

    Article  Google Scholar 

  17. 17.

    Bhattacharyya B, Doloi BN, Sorkhel SK (1999) Experimental investigations into electrochemical discharge machining (ECDM) of nonconductive ceramic materials. J Mater Process Technol 95:145–154

    Article  Google Scholar 

  18. 18.

    Rattan N, Mulik RS (2017) Experimental investigations and multi-response optimization of silicon dioxide (quartz) machining in magnetic field assisted TW-ECSM process. Silicon 9(5):663–673

    CAS  Article  Google Scholar 

  19. 19.

    Jain VK, Priyadarshini D (2014) Fabrication of microchannels in ceramics (quartz) using electrochemical spark micromachining (ECSMM). J Adv Manuf Syst 13(01):5–16

    Article  Google Scholar 

Download references

Acknowledgments

Authors are thankful to Mr. S.B. Yadaw DMSRDE Kanpur, India, for providing facilities for fabrication of Silica Epoxy Nanocomposite material.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Pallvita Yadav.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Yadav, P., Yadava, V. & Narayan, A. Experimental Investigation for Performance Study of Wire Electrochemical Spark Cutting of Silica Epoxy Nanocomposites. Silicon 12, 1023–1033 (2020). https://doi.org/10.1007/s12633-019-00197-3

Download citation

Keywords

  • Polymer nanocomposite
  • Silicon dioxide epoxy nanocomposite
  • MRR
  • Wire electrochemical spark cutting (WECSC) process