INFLUENCE OF WIRE-EDM PARAMETERS ON SURFACE CHARACTERISTICS OF SUPERALLOY MONEL 400

2022 ◽  
Author(s):  
N. E. ARUN KUMAR ◽  
A. SURESH BABU ◽  
M. SUBRAMANIAN ◽  
C. PRADEEP KUMAR
Keyword(s):  
Surface Finish ◽  
Surface Characteristics ◽  
Input Current ◽  
Clear Understanding ◽  
Progressive Development ◽  
Complex Shapes ◽  
Monel 400 ◽  
Increasing Demand ◽  
Machining Strategies ◽  
Wire Feed

Progressive development in the industrial field leads to the increasing demand for superalloys with enhanced mechanical properties, such as toughness, hardness, ductility, damping strength, tensile strength and improved surface finish. Monel 400, one of such superalloys, with the majority of its application in aerospace and marine fields demands a good super finish. There arises the need for some nonconventional processes like WEDM. This process is more effective to obtain complex shapes to close tolerance. This research focuses on clear understanding of the machining strategies with proper parametric combinations to achieve an improved surface finish, subsequently reducing the time and expense involved in the superfinishing procedure. The surface qualities of the selected samples are validated with the help of roughness profile and topography images. This study has proven that the increasing input current and wire feed rate (WFR) consistently decreases the surface roughness (SR; [Formula: see text] of the specimen. This paper also explains the effect of topographic parameters and microstructure over the resulting SR. In addition, the consistent contribution of WFR and input current toward the lower SR is established. The relationship between morphological behavior and parametric deviations is evaluated. A significant correlation found to exist between the rate of wire feed and the height parameters of SR such as [Formula: see text], [Formula: see text], etc.

Spatial Filter Design for Dual-Stage Systems

2017 ◽  
Author(s):  
Aleksandra Mitrovic ◽  
Kam K. Leang ◽  
Garrett M. Clayton
Keyword(s):  
Long Range ◽  
High Speed ◽  
Filter Design ◽  
Spatial Filter ◽  
Control Allocation ◽  
Clear Understanding ◽  
Positioning Systems ◽  
Significant Research ◽  
Dual Stage ◽  
Increasing Demand

Increasing demand for high precision positioning systems has motivated significant research in this field. Within this field, dual-stage nanopositioning systems have the unique potential to offer high-speed and long-range positioning by coupling a short-range, high-speed actuator with a long-range, low-speed actuator. In this paper, design considerations for a spatial filter are presented. The spatial filter allows for control allocation based on range of the signal as opposed to more commonly used frequency-based control allocation. In order to understand the spatial filtering approach more fully, this paper analyzes the filter in detail to understand limitations and give the user a more clear understanding of the approach. Simulation results are included to illustrate aspects of the discussion.

scholarly journals Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

2020 ◽  
Vol 10 (6) ◽  
pp. 2082 ◽  
Author(s):  
Jaber E. Abu Qudeiri ◽  
Aiman Zaiout ◽  
Abdel-Hamid I. Mourad ◽  
Mustufa Haider Abidi ◽  
Ahmed Elkaseer
Keyword(s):  
Large Scale ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Future Research ◽  
Process Conditions ◽  
Process Performance ◽  
Die Steels ◽  
Wide Range ◽  
Complex Shapes ◽  
Manufacturing Technologies

Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

Performance and Analysis of Silicon Mixed Kerosene Servotherm in EDM of Monel 400

2015 ◽  
Vol 766-767 ◽  
pp. 674-680
Author(s):  
P. Karunakaran ◽  
J. Arun ◽  
V. Palanisamy ◽  
N.R.R. Anbusagar ◽  
P. Sengottuvel
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Silicon Powder ◽  
Graphite Powder ◽  
Dielectric Medium ◽  
Tool Wear Rate ◽  
Good Surface ◽  
Good Surface Finish ◽  
Monel 400

Improving the Material Removal Rate (MRR), reduce Tool Wear Rate (TWR), achieve the good Surface Finish (SF) and Over Cut (OC) are very demanding in Electrical Discharging Machining (EDM). This paper focused on performance of Silicon powder mixed with kerosene servotherm dielectric medium in EDM of Monel 400. The optimum range of Silicon powder, Graphite powder 6g mixes with the dielectric medium of kerosene servotherm (75:25) were developed experimentally. It was reported slightly more MRR, very low TWR, better OC and good surface finish (SF) in Monel 400.

Atomic Force Microscopy Study on WC 14Co and WC 14Co+CNT Coated Surfaces

2015 ◽  
Vol 766-767 ◽  
pp. 573-578
Author(s):  
K.N. Balan
Keyword(s):  
Atomic Force Microscopy ◽  
Surface Finish ◽  
Spray Coating ◽  
Surface Characteristics ◽  
Microscopy Study ◽  
Thermal Spray Coating ◽  
Force Microscopy ◽  
Coating Technique ◽  
Atomic Force ◽  
Detonation Gun

There are several methods to improve surface characteristics. Detonation Gun coating (D-Spray) is one of the popular method in thermal spray coating technique. Generally, to enhance the surface properties like wear and corrosion resistance, microhardness, surface finish etc.. D-Spray process was preferred. In this present study, the property of surface finish was considered for the coating powders of WC 14Co and WC 14Co+CNT. The Powder WC 14Co+CNT was prepared in a systematic way and coating process was carried out by using detonation gun coating technique. Scanning Electron Microscopy (SEM) had been done on the powders of with and without CNT and Atomic force Microscopy (AFM) analysis on the surface was done for various places on the surface. A significant effect on the surface finish was exhibited.

scholarly journals Optimization of parameters in cylindrical and surface grinding for improved surface finish

2018 ◽  
Vol 5 (5) ◽  
pp. 171906 ◽  
Author(s):  
Dinesh Kumar Patel ◽  
Deepam Goyal ◽  
B. S. Pabla
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Finish ◽  
Surface Characteristics ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cylindrical Grinding ◽  
Grinding Parameters ◽  
Wheel Material

Surface integrity has attracted the attention of researchers for improving the functional performance of engineering products. Improvement in surface finish, one of the important parameters in surface integrity, has been attempted by researchers through different processes. Grinding has been widely used for final machining of components requiring smooth surfaces coupled with precise tolerances. Proper selection of grinding wheel material and grade with grinding parameters can result in an improved surface finish and improved surface characteristics. The present work reports the study of the effect of grinding parameters on surface finish of EN8 steel. Experiments were performed on surface grinding and cylindrical grinding for optimization of grinding process parameters for improved surface finish. Grinding wheel speed, depth of cut, table feed, grinding wheel material and table travel speed for surface grinding operation, and work speed for cylindrical grinding operation were taken as the input parameters with four types of grinding wheels (Al 2 O 3 of grades K and L, and white alumina of grades J and K). The surface roughness was taken as an output parameter for experimentation. The grinding wheel material and grade have been observed to be the most significant variables for both cylindrical grinding and surface grinding. Surface roughness in the case of surface grinding is better compared to that of cylindrical grinding, which can be attributed to vibrations produced in the cylindrical grinding attachment. Surface roughness ( R a ) values of 0.757 µm in cylindrical grinding and 0.66 µm in surface grinding have been achieved.

Wear Behavior in Wire of Wire Cut EDM

2014 ◽  
Vol 704 ◽  
pp. 70-76
Author(s):  
Ruma Sen ◽  
P. Charkraborti ◽  
J. Debbarma
Keyword(s):  
Electrical Discharge Machining ◽  
Wear Behavior ◽  
Machining Process ◽  
Machining Processes ◽  
Wire Tension ◽  
Complex Shapes ◽  
Sharp Edges ◽  
Pulse On Time ◽  
Wedm Process ◽  
Wire Feed

Wire electrical discharge machining (WEDM) is a specialized thermal machining process, capable of accurately machining parts with different hardness, complex shapes and sharp edges that are very difficult to be machined by the traditional machining processes. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted noncontact technique of material removal.In this paper, the effects of various process parameters of WEDM like pulse on time (Ton), peak current (IP), wire feed (WF) and wire tension (WT) have been investigated to study their impact on wear of wire of ELECTRONICA SPRINTCUT WEDM machine.It is found that the wear is influenced with increase in pulse on time (Ton) and wire tension.

scholarly journals Extrusion 3D Printing of Polybutyrate-Adipate-Terephthalate-Polymer Composites in the Pellet Form

Polymers ◽  
2018 ◽  
Vol 10 (8) ◽  
pp. 922 ◽  
Author(s):  
Sarat Singamneni ◽  
Dawn Smith ◽  
Marie-Joo LeGuen ◽  
Derryn Truong
Keyword(s):  
3D Printing ◽  
Wood Flour ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Complex Shapes ◽  
Increasing Demand ◽  
Pellet Form ◽  
3D Printing Technique

Fused deposition modelling is a common 3D printing technique used for the freeform fabrication of complex shapes based on polymers. Acrylonitrile butadiene styrene (ABS) is the common material option, though polylactide (PLA) has also proved to be a successful candidate. There is an ever increasing demand to harness new materials as possible candidates for fused deposition. The current research is focused on evaluating polybutyrate-adipate-terephthalate–polymer (PBAT) for fused deposition modelling. Both neat and composite PBAT filled with varying wood flour fillers were experimentally analyzed for 3D printing by extrusion from the pellet forms. The results are positive and the addition of small quantities of the wood flour filler material was found to improve the thixotropic nature of the polymer composite and consequently the inter-strand and inter-layer coalescence.

Some Investigations on Surface Texturing on Monel 400 Using Photochemical Machining

2015 ◽  
Author(s):  
Sadaiah Mudigonda ◽  
Deepakkumar H. Patil
Keyword(s):  
Surface Finish ◽  
Surface Texturing ◽  
Machining Process ◽  
Etching Time ◽  
Temperature Influence ◽  
Surface Textures ◽  
Monel 400 ◽  
The Creation ◽  
Spinning Speed

This paper reports the creation of surface textures using Photochemical Machining Process (PCM) on Monel 400. Machining is carried out on Monel 400 sheets. The influence of the photolithography parameters and spinning speed on the photoresist films were investigated. The etching media used is HNO3:FeCl3:H2O = 30ml: 500g: per liter concentration. The effects of etching time and temperature on the etched topography pattern were studied. It has been observed that time has more influence on the depth of etch as compared to temperature. However temperature influence surface finish more.

Optical Surface Finish of PCD Composites by Dynamic Friction Polishing

2007 ◽  
Vol 364-366 ◽  
pp. 226-231 ◽  
Author(s):  
Y. Chen ◽  
Liang Chi Zhang ◽  
Joseph A. Arsecularatne
Keyword(s):  
Surface Finish ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Surface Characteristics ◽  
Cost Effective ◽  
Dynamic Friction ◽  
Optical Surface ◽  
Surface Characterisation ◽  
Fold Reduction ◽  
Cost Effective Technique

This paper presents a cost-effective technique for achieving optical surface finish of thermally stable polycrystalline diamond (PCD) composites using dynamic friction polishing (DFP). The effect of polishing parameters on the material removal rate and surface characteristics of polished specimens were studied. The surface characterisation was carried out by optical microscopy, atomic force microscopy (AFM), scanning electron microscope (SEM) and its attached energy dispersive X-ray (EDX) analysis. It was found that optical surface finish of PCD with roughness Ra = 50 nm could be obtained efficiently with nearly a ten fold reduction in polishing time compared to the currently used method in industry.

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