SURFACE MORPHOLOGY OF SILICON NITRIDE (Si3N4)-TITANIUM NITRIDE (TiN) COMPOSITES USING GRA-RSM STRATEGY ENCOMPASSED WITH EDMed PARAMETERS

L. Selvarajan, K. Venkataramanan (), S. Kannan (), S. Senthil Kumar (), K. P. Srinivasa Perumal (), P. Mathan Kumar (), N. L. Parthasarathi, N. Kasthuri (), Katherasan Duraisamy () and C. Arun ()
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L. Selvarajan: Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Mallasamudram West, Namakkal 637503, Tamil Nadu, India
K. Venkataramanan: ��Department of Mechanical Engineering, Mahendra Polytechnic College, Mallasamudram West, Namakkal 637503, Tamil Nadu, India
S. Kannan: Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Mallasamudram West, Namakkal 637503, Tamil Nadu, India
S. Senthil Kumar: ��Department of Mechanical Engineering, SRM Institute of Science and Technology, Tiruchirappalli Campus, Tiruchirappalli 621105, Tamil Nadu, India
K. P. Srinivasa Perumal: �Department of Mechanical Engineering, Mahendra Engineering College (Autonomous), Namakkal District, Tamil Nadu – 637 503, India
P. Mathan Kumar: �Department of Mechanical Engineering, Bannari Amman Institute of Technology (Autonomous), Erode District, 638401, Tamil Nadu, India
N. L. Parthasarathi: ��High-temperature Materials Technology Section, Indira Gandhi Centre for Atomic Research, Kalpakkam-603102, Tamil Nadu, India
N. Kasthuri: *Department of Electronics and Communication Engineering, Government Polytechnic College, Thuvakudimalai, Tiruchirappalli-620022, Tamil Nadu, India
Katherasan Duraisamy: ��†Department of Aeronautical Engineering, Dhanalakshmi Srinivasan Engineering College, Perambalur 621212, Tamil Nadu, India
C. Arun: Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Mallasamudram West, Namakkal 637503, Tamil Nadu, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 11, 1-23

Abstract: This investigation explores the application of electrical discharge machining (EDM) to ceramic composites constructed from Si3N4–TiN (Syalon 501) by testing both square and cylindrical electrodes. Various experimental methods have been employed, including design-of-experiments (DoE), Grey relational analysis (GRA), analysis of variance (ANOVA), confirmation testing, and scanning electron microscopy (SEM), in an effort to optimize machining settings and comprehend their effect on performance. While ANOVA revealed crucial parameter levels influencing overall machining conditions as measured by the grey relational grade (GRG), the sophisticated method of GRA considerably improved the machining characteristics. Significant improvements in the EDM process were shown experimentally, resulting in outstanding results for material removal rate (MRR), surface roughness (SR), and electrode wear rate (EWR). In particular, numerous benefits of the square electrode layout over the more common cylindrical arrangement stood out. All of the aforementioned resulted in an impressively high MRR (measured at 0.0281 gm/min), a low EWR (at 0.0020 gm/min), and a significant improvement in SR (at 0.3150 μm). The GRG value was 0.0163 for the square electrode design, which was excellent, and 0.0025 for the cylindrical electrode, which was significantly better. The optimized parameters were successfully used, especially with the square electrode arrangement, leading to significant improvements in MRR and decreases in EWR. On the other hand, surface quality was negatively affected by larger parameter values, which increased the development of microfractures, particularly when using the square electrode design. In any case, our study provides strong proof that adjusted settings can greatly improve EDM performance, allowing for accurate machining of Si3N4–TiN composites with increased MRR, great surface texture, and reduced electrode wear. In conclusion, our study provides useful information to improve EDM procedures for Si3N4–TiN ceramic composites, as well as practical insights into increasing the efficiency and quality of EDM operations in a variety of industrial sectors.

Keywords: EDM; MRR; SR; GRA; ANOVA; surface texture (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X25500039

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