Experimental Investigations and Statistical Modeling of Ultrasonic Assisted Jet Electrochemical Micro-Drilling Process with Pulsed DC

2019 ◽  
Vol 18 (03) ◽  
pp. 413-434
Author(s):  
Harsha Goel ◽  
Pulak M. Pandey
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Experimental Investigations ◽  
Drilling Process ◽  
Dc Voltage ◽  
Pulsed Dc ◽  
Crucial Effect ◽  
Ultrasonic Assisted ◽  
Micro Drilling ◽  
Pulse On Time

This article presents an experimental study of a recently developed process, namely, ultrasonic assisted jet electrochemical micro-drilling (UAJet-ECMD) using pulsed DC voltage power supply. The goal of the work was to examine the effect of pulsed DC voltage on the performance of UAJet-ECMD process. In the previous work carried out by the authors, the process has been studied using the continuous DC voltage. The pulse “on” time (pulsed DC voltage), electrolyte pressure and pulse “on” time (ultrasonic vibrations) were selected as the process parameters, whereas material removal rate (MRR) and hole taper were chosen as process responses. It was found that the pulse “on” time (pulsed DC voltage) had crucial effect on the MRR as well as on the hole taper. MRR and hole taper were both found to increase with rise in pulse “on” time (pulsed DC voltage). Optimization of process responses of UAJet-ECMD process was done. The responses obtained for optimized set of process parameters were verified and found in good conformity with the experimental results.

Experimental investigations into ultrasonic-assisted double-disk magnetic abrasive finishing of two paramagnetic materials

2015 ◽  
Vol 231 (6) ◽  
pp. 1021-1038 ◽  
Author(s):  
Prateek Kala ◽  
Pulak M Pandey
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Experimental Investigations ◽  
Magnetic Abrasive Finishing ◽  
Force Microscopy ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Ultrasonic Assisted ◽  
Paramagnetic Materials ◽  
Pulse On Time

This article evaluates the finishing performance of ultrasonic-assisted double-disk magnetic abrasive finishing process on two paramagnetic materials (copper alloy and stainless steel) with different mechanical properties such as flow stress, hardness, shear modulus, and so on. The finishing experiments were performed based on response surface methodology. The results obtained after finishing have been analyzed to determine the effect of different process parameters such as working gap, rotational speed, and pulse-on time of ultrasonic vibration for both work materials and to study various interaction effects that may significantly affect the finishing performance by the process. The outcome of analysis for the two different work materials has been critically compared to understand the effect of the considered process parameters on the finishing performance of the process based on mechanical properties of the workpiece such as hardness. Furthermore, the scanning electron microscopy and atomic force microscopy were carried on the workpiece surface to understand the possible mechanism of material removal and the surface morphology produced after the finishing process.

Modelling and simulation of ultrasonic-assisted jet electrochemical micro drilling process

2019 ◽  
Vol 233 (12) ◽  
pp. 4199-4212
Author(s):  
Harsha Goel ◽  
Usharani Rath ◽  
Pulak M Pandey
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Modelling And Simulation ◽  
Drilling Process ◽  
Ultrasonic Assisted ◽  
Micro Holes ◽  
Micro Drilling ◽  
Experimental Findings ◽  
Electrolyte Jet

Ultrasonic-assisted jet electrochemical micro drilling is an advanced variant of electrochemical machining to drill micro holes quickly and efficiently. The present article deals with the modelling and simulation of the integration of ultrasonic vibration with the conventional jet electrochemical micro drilling process. Multi-physics-based modelling and simulation approach has been used in the present work. The flow pattern of electrolyte jet was analysed for both jet electrochemical micro drilling and ultrasonic-assisted jet electrochemical micro drilling processes. The simulation results were validated with the previous experimental findings of ultrasonic-assisted jet electrochemical micro drilling process. It was found that the material removal rate (MRR) improved significantly as the ultrasonic wave got superimposed onto the electrolyte jet. In addition to that, voltage and concentration of the electrolyte also played vital roles in improving the MRR.

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

scholarly journals Multi-Objective Optimization of Process Parameters for Powder Mixed Electrical Discharge Machining of Inconel X-750 Alloy Using Taguchi-Topsis Approach

2021 ◽  
Vol 71 (1) ◽  
pp. 1-18
Author(s):  
Basha Shaik Khadar ◽  
Raju M. V. Jagannadha ◽  
Kolli Murahari
Keyword(s):  
Boron Carbide ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

Experimental investigations on surface finish and microgeometry of helical gear in pulsed-electrochemical honing process

2019 ◽  
Vol 233 (10) ◽  
pp. 3364-3375 ◽  
Author(s):  
Pravin Rai ◽  
Neelesh K Jain ◽  
Sunil Pathak
Keyword(s):  
Surface Finish ◽  
Removal Rate ◽  
Experimental Investigations ◽  
Helical Gears ◽  
Mechanical Parts ◽  
Sandwich Type ◽  
Mechanical Elements ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Gear is one of the most vital mechanical elements for transmission of power and motion. It has been considered as one of the highest consumable mechanical parts. Surface attributes of the gears are most important elements to describe its operating performance, service life, and accuracy. Present work highlights the development of pulsed-electrochemical honing process to enhance the performance of gears by refining the variables of surface roughness, microgeometry, and material removal rate of 20MnCr5 alloy steel helical gears. Freshly designed sandwich type cathode gear has been developed which served as a tool in pulsed-electrochemical honing process. Investigations have been done on studying the effects and identifying the optimum values of four most important variables of pulsed-electrochemical honing process, namely applied voltage ( V), pulse-on time ( T on), pulse-off time ( T off), and finishing time ( t) on synchronized enhancement in surface finish and microgeometry. Results of the investigations reveal that T on as 6 ms, T off as 3 ms, t as 8 min, and V as 16 V yielded the best results for surface finish and microgeometry together.

Effect of WEDM process parameters on machinability of Nimonic75 alloy using brass wire

2020 ◽  
Vol 17 (3) ◽  
pp. 389-397
Author(s):  
Harvinder Singh ◽  
Vinod Kumar ◽  
Jatinder Kapoor
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Content Type ◽  
Response Characteristics ◽  
Nickel Based Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Purpose This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly used in the aerospace industry for its strength at high temperature. Design/methodology/approach One factor at a time (OFAT) approach has been used to perform the experiments. Pulse on time, pulse off time, peak current and servo voltage were chosen as input process parameters. Cutting speed, material removal rate and surface roughness (Ra) were selected as output performance characteristics. Findings Through experimental work, the effect of process parameters on the response characteristics has been found. Results identified the most important parameters to maximize the cutting speed and material removal rate and minimize Ra. Originality/value Very limited research work has been done on WEDM of Nickel-based alloy Nimonic75. Therefore, the aim of this paper to conduct preliminary experimentation for identifying the parameters, which influence the response characteristics such as material removal rate, cutting speed, Ra, etc. during WEDM of Nickel-based alloy (Nimonic75) using OFAT approach and found the machinability of Nimonic75 for further exhaustive experimentation work.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

Multi Response Optimization of Electrical Discharge Machining Process Parameters Using Sintered Copper Electrode

2012 ◽  
Vol 622-623 ◽  
pp. 19-24
Author(s):  
P. Balasubramanian ◽  
Thiyagarajan Senthilvelan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Sintered Copper ◽  
Response Optimization ◽  
Electric Pressure ◽  
Pulse On Time

In this study, input parameters of Electrical Discharge machining (EDM) process have been optimised for two different materials EN-8 and Die steel-D3 were machined by using sintered copper electrode. Analysis of variance (ANOVA) was applied to study the influences of process parameters viz: - peak current, pulse on time, di-electric pressure and diameter of electrode on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) for both materials. Response surface methodology (RSM) has been applied to optimise the multi responses in order to get maximum MRR, minimum TWR and minimum SR. Furthermore, mathematical model has been formulated to estimate the corresponding output responses for both work pieces. It has been observed that compared to EN 8 material, the MRR value is low and TWR is high for D3 material. However the SR value is marginally lower than obtained in EN8.R2 value is above 0.90 for both work pieces.

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