Analysis of temperature distribution in wire electrical discharge machine on hybrid Al-MMCs

Abstract

Wire electrical discharge machine (WEDM) is a non-traditional machining technique for producing parts with higher accuracy Al6061 reinforced with 7% silicon carbide and 3% boron carbide is selected as a work-piece and molybdenum wire as an electrode in this work. The machining in WEDM may result in work-piece surface damage and this is due to the materials thermal properties. The work-piece surface consists of voids, cracks and residual thermal stress after machining due to the spark which is used in machining process. The materials which are machined in WEDM are used in aerospace applications. Particle reinforced aluminium metal matrix composites (Al-MMCs) are used as Fan Exit Guide vane in aerospace gas turbine engine and they are operating at very high temperature. The catastrophic failure may happen due to the availability of thermal damage layer. In this work, the WEDM is modelled based on the finite element method program by using the machining parameters such as voltage, current and pulse on time. In order to reduce the thermal damage layer, the set of parameter which is having the least temperature distribution on the material is analysed. It is determined that, the least temperature distribution over the material results in the least thermal damage layer thickness.