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<p>In this work, powders of AZ31 are blended with nano titanium carbide (nTiC) particles (1, 2, and 3 wt.%) using powder metallurgy (PM) route under an inert atmosphere in a high-energy ball mill, compacted at 20 tons, and sintered under 500&#xa0;°C for 2&#xa0;h. As per ASTM standards, the samples are subjected to porosity, hardness and compression tests. Wire-electrical discharge machining (WEDM) studies are performed as per Taguchi’s L<sub>9</sub> array considering discharge current (DI), pulse off-time (P<sub>off</sub>), and pulse on-time (P<sub>on</sub>), over surface roughness (SR), material removal rate (MRR), and kerf width (KW). Micrographs of specimens show near uniform dispersal of nTiC, with 2 wt.% nTiC addition producing lower porosity and higher hardness and compression strength. WEDM experimental outcomes show that P<sub>on</sub> influences SR and KW, and the influence of DI is higher for MRR. The machined surface shows craters and debris due to melting and vaporization. The ideal condition from desirability analysis is P<sub>on</sub> of 40 µs, P<sub>off</sub> of 20 µs, and DI of 15.63&#xa0;A, which predicts an MRR of 0.078&#xa0;g/min, SR of 2.555&#xa0;μm, and KW of 0.343&#xa0;mm. Linear regression mathematical models developed were given as input to the nature-inspired metaheuristics hippopotamus optimization algorithm (HOA), which provides the ideal conditions of P<sub>on</sub> of 43.18 µs, P<sub>off</sub> of 21.31 µs, and DI of 11.44&#xa0;A. Compared to the experimental values of RSM-desirability analysis, the SR, KW, and MRR values obtained from ideal HOA conditions are lower by 6.38%, 14.68%, and 5.56%.</p> Graphical abstract <p></p>

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Optimizing the control settings in wire electrical discharge machining of magnesium nanocomposite prepared by powder metallurgy

  • 期刊论文

  • 发表日期：

    2025年7月10日

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  • N. Senthilkumar,
  • P. Vasanthkumar,
  • A. Venkatakrishna,
  • G. Perumal,
  • U. Mohamed Iqbal

摘要

In this work, powders of AZ31 are blended with nano titanium carbide (nTiC) particles (1, 2, and 3 wt.%) using powder metallurgy (PM) route under an inert atmosphere in a high-energy ball mill, compacted at 20 tons, and sintered under 500 °C for 2 h. As per ASTM standards, the samples are subjected to porosity, hardness and compression tests. Wire-electrical discharge machining (WEDM) studies are performed as per Taguchi’s L9 array considering discharge current (DI), pulse off-time (Poff), and pulse on-time (Pon), over surface roughness (SR), material removal rate (MRR), and kerf width (KW). Micrographs of specimens show near uniform dispersal of nTiC, with 2 wt.% nTiC addition producing lower porosity and higher hardness and compression strength. WEDM experimental outcomes show that Pon influences SR and KW, and the influence of DI is higher for MRR. The machined surface shows craters and debris due to melting and vaporization. The ideal condition from desirability analysis is Pon of 40 µs, Poff of 20 µs, and DI of 15.63 A, which predicts an MRR of 0.078 g/min, SR of 2.555 μm, and KW of 0.343 mm. Linear regression mathematical models developed were given as input to the nature-inspired metaheuristics hippopotamus optimization algorithm (HOA), which provides the ideal conditions of Pon of 43.18 µs, Poff of 21.31 µs, and DI of 11.44 A. Compared to the experimental values of RSM-desirability analysis, the SR, KW, and MRR values obtained from ideal HOA conditions are lower by 6.38%, 14.68%, and 5.56%.

Graphical abstract