Analysis on topography and metallurgical aspects of EDMed work surface of Inconel 718 obtained using triangular cross sectioned copper tool electrode

2017 ◽  
Author(s):  
Thrinadh Jadam ◽  
Chandramani Upadhyay ◽  
Saurav Datta ◽  
Soumya Gangopadhyay ◽  
Siba Sankar Mahapatra
Keyword(s):  
Inconel 718 ◽  
Tool Electrode ◽  
Work Surface

Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

2019 ◽  
Vol 969 ◽  
pp. 644-649
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Work Piece ◽  
Tool Electrode ◽  
Affecting Factors ◽  
Inconel 718 Alloy ◽  
Electrical Discharge Drilling ◽  
Pulse On Time

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

A Comparative Study of EDD and PM-EDD in Producing Holes in Inconel 718 Alloy

2020 ◽  
Vol 833 ◽  
pp. 48-53
Author(s):  
Rahul Davis ◽  
Abhishek Singh ◽  
Sabindra Kachhap ◽  
Neeraj Nath
Keyword(s):  
Thermal Conductivity ◽  
Comparative Study ◽  
Electric Discharge ◽  
Inconel 718 ◽  
Elevated Temperatures ◽  
Removal Rate ◽  
Chemical Properties ◽  
Tool Electrode ◽  
Inconel 718 Alloy ◽  
Pulse On Time

In recent times, aerospace, chemical industries and nuclear plant have usually used Inconel 718 alloy because of its excellent mechanical and chemical properties at elevated temperatures. It falls under the category of difficult-to-cut materials due to its high toughness, poor thermal conductivity and high hardness. The set-ups for electric discharge drilling (EDD) and powder-mixed electric discharge drilling (PM-EDD) were developed, and experiments were conducted on them separately. This research shows a comparative study amid producing holes by EDD and PM-EDD in Inconel 718 alloy workpiece with copper tool electrode. SiC was used as an abrasive powder because of its better thermal conductivity in order to get properly mixed with dielectric in a separate tank. Output response was assessed in the form of material removal rate, under the influence of discharge current, duty factor, pulse-on-time and tool speed, as the input parameters.

Estimation of Residual Stresses and Crater Shape in µ-EDM by Finite Element Method

2012 ◽  
Author(s):  
Jose Mathew ◽  
Allesu K. ◽  
Shravani Srisailam ◽  
K. P. Somashekhar ◽  
Prakash Naidu P. ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Inconel 718 ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Workpiece Material ◽  
Electrically Conductive ◽  
3 Dimensional ◽  
Spark Erosion ◽  
Crater Morphology ◽  
Good Agreement

Micro-Electric Discharge Machining (μ-EDM) is the process of machining electrically conductive materials in the form of micro-size craters by using precisely controlled sparks that occur between tool electrode and workpiece in the presence of dielectric fluid. The present paper attempts to predict the accurate model for thermal behavior of the EDM process on commercially available Inconel 718. The temperature gradients are crucial in identifying the zones of high temperature and high residual stresses. 3-Dimensional, transient coupled (structural and thermal) analysis is modeled for Inconel 718 workpiece material to estimate the residual stresses due to spark erosion and also to study the crater morphology. The residual stresses are higher at the centre of the crater and it is decreasing when move far from the centre. The simulated results are compared with the experimental results. Both the experimental and the simulated results are in good agreement.

Micro-EDM Deposition Alloying Process

2004 ◽  
Author(s):  
Ricardo I. Ori ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Takashi Nakamura ◽  
Shun-ichiro Tanaka
Keyword(s):  
Electrical Discharge ◽  
Metal Electrode ◽  
Medium Carbon Steel ◽  
Tool Electrode ◽  
Micro Edm ◽  
Cross Sectional ◽  
Medium Carbon ◽  
X Ray ◽  
Work Surface ◽  
Eds Analysis

A new deposition alloying process using Micro-EDM was developed. Using the energy released by the electrical discharge, material from the tool electrode is melted and deposited over the work surface. When a rotating bi-metal tool electrode is fed towards the work surface, the alloying between its elements occurs during process. The obtained results of the alloying between nickel and iron are presented in the present paper, when the components of the bi-metal tool electrode are made of YNi-1 (nickel alloy used in TIG welding — JIS standard) and medium carbon steel (S45C — JIS standard). X-ray and EDS analysis have shown that the chemical composition of the obtained deposit can be controlled and is proportional to the cross sectional area of each element present in the bi-metal electrode. With this process, a material with the same composition of Invar was successfully deposited.

Through hole making by electro-discharge machining on Inconel 625 super alloy using hollow copper tool electrode

2018 ◽  
Vol 233 (2) ◽  
pp. 348-370 ◽  
Author(s):  
Dileep Kumar Mishra ◽  
▪ Rahul ◽  
Saurav Datta ◽  
Manoj Masanta ◽  
Siba Sankar Mahapatra
Keyword(s):  
Matrix Material ◽  
Inconel 625 ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
X Ray ◽  
Work Surface ◽  
Electro Discharge Machining ◽  
Hole Making ◽  
Through Hole ◽  
Super Alloy

A case experimental research on through hole making process on Inconel 625 super alloy by using hollow (tubular) copper tool electrode in electro-discharge machining has been delineated herein. Based on three controllable process variables namely peak discharge current, pulse-on duration, and gap voltage, experiments on through hole making have been carried out following the electro-discharge machining route (die-sinking electro-discharge machining without flushing). In addition to surface morphology, topographical features of the electro-discharge machined work surface have been examined for both internal cylindrical surface of the hole produced and also the external peripheral surface of the removed cylindrical part. The influence of the process parameters have been analyzed on various process performance features like material removal rate, surface roughness, surface crack density, white layer thickness, circularity, radial overcut, and hole taper. An optimal parameter setting has been identified for sound hole making and thereby to improve electro-discharge machining performance. Additionally, energy-dispersive X-ray spectroscopic analysis has been carried out to investigate the extent of carbon enrichment onto the electro-discharge machined work surface of Inconel 625 as affected by the pyrolysis of the dielectric fluid whilst executing electro-discharge machining operation. X-ray diffraction tests have been carried out to compare metallurgy of the electro-discharge machined work surface (various phases/precipitates present in bulk of the matrix material, extent of grain refinement, crystallite size, strain, and dislocation density) with respect to that of “as received” Inconel 625. Results, thus obtained, have also been compared to that of the micro-hardness test data.

Investigation of Surface Roughness for Inconel 718 in Blind Hole Drilling with Rotary Tool Electrode

2019 ◽  
Vol 18 (03) ◽  
pp. 379-394
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Work Piece ◽  
Tool Electrode ◽  
Tool Diameter ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Tool Rotation ◽  
Off Time ◽  
Time Pulse

The research investigation reported on the effect of machining parameters on surface roughness (Ra) in electric discharge drilling of Inconel 718. Machining was done by using a copper tool electrode. Machining was conducted by considering different process parameters viz. tool diameter, discharge current, pulse on time, pulse off time, tool rotation and depth of hole. Optical surface profiler was used to measure surface roughness of drilled hole in work-piece. Design of experiment was created by Taguchi method based L18 orthogonal array. For minimum surface roughness, optimum parameters were found using Analysis of variance (ANOVA). Based on analysis, it is found that pulse off time, pulse on time and tool rotation are the most significant parameters that affect the surface roughness. Tool diameter is the less significant parameter that affects the surface roughness. Regression analysis was used to predict a value for minimum surface roughness. The scanning electron microscope (SEM) images were used to identify the microstructure of the drilled hole in Inconel 718 work-piece. Interaction plots and residual plot have been plotted for surface roughness to identify the interaction between parameters and residual errors, respectively.

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