Lafta, S., Ibrahim, A. (2025). Investigation of machining performance in ecdm of Al6061-SiC-B4C hybrid composites. , 43(6), 444-458. doi: 10.30684/etj.2025.156592.1881
Safa M. Lafta; Abbas F. Ibrahim. "Investigation of machining performance in ecdm of Al6061-SiC-B4C hybrid composites". , 43, 6, 2025, 444-458. doi: 10.30684/etj.2025.156592.1881
Lafta, S., Ibrahim, A. (2025). 'Investigation of machining performance in ecdm of Al6061-SiC-B4C hybrid composites', , 43(6), pp. 444-458. doi: 10.30684/etj.2025.156592.1881
Lafta, S., Ibrahim, A. Investigation of machining performance in ecdm of Al6061-SiC-B4C hybrid composites. , 2025; 43(6): 444-458. doi: 10.30684/etj.2025.156592.1881

Investigation of machining performance in ecdm of Al6061-SiC-B4C hybrid composites

Engineering and Technology Journal
Volume 43, Issue 6, June 2025, Pages 444-458    PDF (1.04 M)
Document Type: Research Paper
DOI: 10.30684/etj.2025.156592.1881
Authors
Safa M. Lafta* ; Abbas F. Ibrahim
Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
Abstract
This study investigates the machining performance of the Electrochemical Discharge Machining (ECDM) process on a hybrid composite material comprising Aluminum 6061 reinforced with 6% silicon carbide (SiC) and 6% boron carbide (B4C). Experiments evaluated the effects of electrolyte concentration, voltage, pulse-on time, and pulse-off time on Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Taguchi analysis and ANOVA highlighted the significant influence of these parameters on machining outcomes. The optimal MRR (0.113 g/min) was achieved at 20% electrolyte concentration, 40V, 150 µs pulse-on time, and 25 µs pulse-off time. The best TWR (0.007 g/min) occurred at 30% concentration, 30V, 150 µs pulse-on time, and 50 µs pulse-off time. The optimal SR (4.757 µm) was observed at 20% concentration, 30V, 100 µs pulse-on time, and 75 µs pulse-off time. The findings emphasize the importance of parameter optimization in improving machining efficiency and surface integrity, offering valuable insights for hybrid composite applications. In particular, the study reveals that higher electrolyte concentrations and voltages generally enhance MRR but can increase TWR and degrade SR. These findings underline the importance of parameter optimization for balancing productivity and surface integrity. This research provides valuable insights for industries seeking precise and efficient machining of hybrid composites, showcasing a 34% enhancement in machining efficiency and a 21% improvement in surface quality using the optimized ECDM conditions.

Highlights
  • ECDM for Al6061-SiC-B4C composites was optimized using Taguchi analysis and ANOVA to enhance machining performance.
  • 34% efficiency, 21% surface quality improvement at 20% electrolyte, 40V, 150µs Pon.
  • MRR and SR were improved, benefiting machining applications in aerospace, automotive, and defense industries.
Keywords
Electrochemical Discharge Machining; Hybrid composite machining; Aluminum 6061; Silicon carbide; Boron carbide
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