Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites
Abstract The traditional way to machine hybrid composites is hard because they tend to break, have a high retraction, have a high service temperature, and have an uneven surface irregularity. For high-strength fiber/metal composite constructions, alternative machining methods have drawn interest as...
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| Format: | Article |
| Language: | English |
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Nature Portfolio
2023-10-01
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| Series: | Scientific Reports |
| Online Access: | https://doi.org/10.1038/s41598-023-44334-w |
| _version_ | 1797576608384548864 |
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| author | R. Selvam M. Subramanian M. Diviya T. M. Yunus Khan Rahmath Ulla Baig Tansir Ahamad Md. Abul Kalam Abdul Razak N. Monish Anteneh Wogasso Wodajo |
| author_facet | R. Selvam M. Subramanian M. Diviya T. M. Yunus Khan Rahmath Ulla Baig Tansir Ahamad Md. Abul Kalam Abdul Razak N. Monish Anteneh Wogasso Wodajo |
| author_sort | R. Selvam |
| collection | DOAJ |
| description | Abstract The traditional way to machine hybrid composites is hard because they tend to break, have a high retraction, have a high service temperature, and have an uneven surface irregularity. For high-strength fiber/metal composite constructions, alternative machining methods have drawn interest as a solution to these problems. Current research focuses on enhancing the Abrasive Water Jet Machining process by optimizing its variables using a composite material of epoxy reinforced with silicon carbide, stainless steel wire mesh, and Kevlar. The variables assessed are the Nozzle-to-substrate gap (S), the Abrasive discharge molding and different percentages of silicon carbide (SiC) filler (0%, 3%, and 6% by weight), three different types of hybrid laminates (H1, H2, and H3) were produced. The response surface method (RSM) was utilized in this learning, specifically on a central composite design, to calculate and optimize machining variables based on the Kerf convergence ratio (Kt) and Surface irregularity (Ra) as responses. According to the results, the traverse feed velocity, Abrasive discharge proportion, and Nozzle-to-substrate gap are the critical factors in determining Surface irregularity and Kerf convergence width (H1 laminate) for a fiber/metal laminate with 0%, 3% and 6% weight fraction. In the case of a 3% weight fraction H2 laminate, the traverse feed velocity was identified as the primary factor affecting the Kerf convergence ratio. In contrast, traverse feed velocity and Nozzle-to-substrate gap had the most significant influence on Surface irregularity. The findings also indicated that S, followed by Abrasive discharge proportion and traverse feed velocity, are the variables that have the most significant influence when cutting 6 wt% SiC filler particle fiber/metal laminate (H3 laminate). For Surface irregularity, the combination of traverse feed velocity and Nozzle-to-substrate gap had the most significant impact. To validate the optimization results, confirmatory tests was conducted, and the findings were very similar to the experimental values, indicating the accuracy and effectiveness of the optimization process. To better understand the manufacturing processes, a scanning electron microscope was used to examine the morphological features of the machined surfaces, such as delamination, fibre breakage, and fibre pull-out. |
| first_indexed | 2024-03-10T21:55:20Z |
| format | Article |
| id | doaj.art-35c888a536f04aa790957e0864846333 |
| institution | Directory Open Access Journal |
| issn | 2045-2322 |
| language | English |
| last_indexed | 2024-03-10T21:55:20Z |
| publishDate | 2023-10-01 |
| publisher | Nature Portfolio |
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| spelling | doaj.art-35c888a536f04aa790957e08648463332023-11-19T13:09:06ZengNature PortfolioScientific Reports2045-23222023-10-0113111810.1038/s41598-023-44334-wEffect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid compositesR. Selvam0M. Subramanian1M. Diviya2T. M. Yunus Khan3Rahmath Ulla Baig4Tansir Ahamad5Md. Abul Kalam6Abdul Razak7N. Monish8Anteneh Wogasso Wodajo9Department of Mechanical Engineering, St. Joseph’s College of EngineeringDepartment of Mechanical Engineering, St. Joseph’s College of EngineeringDepartment of Computer Science and Engineering, Amrita School of Computing, Amrita Vishwa VidyapeethamDepartment of Mechanical Engineering, College of Engineering, King Khalid UniversityDepartment of Industrial Engineering, College of Engineering, King Khalid UniversityDepartment of Chemistry, College of Science, King Saud UniversitySchool of Civil and Environmental Engineering, FEIT, University of Technology SydneyDepartment of Mechanical Engineering, P. A. College of Engineering (Affiliated to Visvesvaraya Technological University, Belagavi)Department of Mechanical Engineering, St. Joseph’s College of EngineeringDepartment of Automotive Engineering, College of Engineering and Technology, Dilla UniversityAbstract The traditional way to machine hybrid composites is hard because they tend to break, have a high retraction, have a high service temperature, and have an uneven surface irregularity. For high-strength fiber/metal composite constructions, alternative machining methods have drawn interest as a solution to these problems. Current research focuses on enhancing the Abrasive Water Jet Machining process by optimizing its variables using a composite material of epoxy reinforced with silicon carbide, stainless steel wire mesh, and Kevlar. The variables assessed are the Nozzle-to-substrate gap (S), the Abrasive discharge molding and different percentages of silicon carbide (SiC) filler (0%, 3%, and 6% by weight), three different types of hybrid laminates (H1, H2, and H3) were produced. The response surface method (RSM) was utilized in this learning, specifically on a central composite design, to calculate and optimize machining variables based on the Kerf convergence ratio (Kt) and Surface irregularity (Ra) as responses. According to the results, the traverse feed velocity, Abrasive discharge proportion, and Nozzle-to-substrate gap are the critical factors in determining Surface irregularity and Kerf convergence width (H1 laminate) for a fiber/metal laminate with 0%, 3% and 6% weight fraction. In the case of a 3% weight fraction H2 laminate, the traverse feed velocity was identified as the primary factor affecting the Kerf convergence ratio. In contrast, traverse feed velocity and Nozzle-to-substrate gap had the most significant influence on Surface irregularity. The findings also indicated that S, followed by Abrasive discharge proportion and traverse feed velocity, are the variables that have the most significant influence when cutting 6 wt% SiC filler particle fiber/metal laminate (H3 laminate). For Surface irregularity, the combination of traverse feed velocity and Nozzle-to-substrate gap had the most significant impact. To validate the optimization results, confirmatory tests was conducted, and the findings were very similar to the experimental values, indicating the accuracy and effectiveness of the optimization process. To better understand the manufacturing processes, a scanning electron microscope was used to examine the morphological features of the machined surfaces, such as delamination, fibre breakage, and fibre pull-out.https://doi.org/10.1038/s41598-023-44334-w |
| spellingShingle | R. Selvam M. Subramanian M. Diviya T. M. Yunus Khan Rahmath Ulla Baig Tansir Ahamad Md. Abul Kalam Abdul Razak N. Monish Anteneh Wogasso Wodajo Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites Scientific Reports |
| title | Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites |
| title_full | Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites |
| title_fullStr | Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites |
| title_full_unstemmed | Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites |
| title_short | Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites |
| title_sort | effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber metal hybrid composites |
| url | https://doi.org/10.1038/s41598-023-44334-w |
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