scholarly journals Feasibility Analysis of Novel Maglev EDM by Comparing with Conventional Micro EDM

2021 ◽  
Author(s):  
Mangal Singh Sisodiya ◽  
Shashank Shukla ◽  
Vivek Bajpai
Keyword(s):  
Titanium Alloy ◽  
Removal Rate ◽  
Pure Titanium ◽  
Machining Process ◽  
Micro Edm ◽  
The Novel ◽  
Novel Technology ◽  
Servo Mechanism ◽  
Similar Range ◽  
Cp Ti

Abstract The Micro EDM is the most suitable machining process in the miniaturization of products at present era. The attainment of close precision is the primary obligation in miniaturization or micromachining. Especially in machining of hard-to-cut materials like titanium alloy. Such alloys are applied in several cutting-edge high-quit applications due to extraordinary properties. Current work presents an exploratory analysis of novel Maglev EDM while machining of commercially used pure titanium alloy (CP-TI). The work outlook is to establish the viability of novel Maglev EDM by comparing the with similar range of micro EDM. The pure DC power is employed with the conjunction of Maglev lucidity to refine the shortcomings of the conventional micro EDM. The novel technology deals with prime concerns of conventional micro EDM and cracked deficiencies like delay response of mechanical actuator and a servo mechanism. The Novel technology uses the logical arrangement of permanent and electromagnet to dealt with inadequacies like short-circuiting and arcing. The results of state of art novel technology proclaimed the improved Material removal rate (MRR), which are lying in the average range of 76.6 µgm/min, whereas the specific energy and surface roughness are observed 33.4 Joule/ microgram and 4.3 µm respectively.

Research of PZT Excited Discharge Channel Compression Micro-EDM Techniques

2013 ◽  
Vol 645 ◽  
pp. 363-366
Author(s):  
Lian Ming Du ◽  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Ya Zhang
Keyword(s):  
Discharge Channel ◽  
Removal Rate ◽  
New Technology ◽  
Machining Process ◽  
Micro Edm ◽  
System Composition ◽  
The Stability ◽  
Discharge Gap ◽  
Edm Process ◽  
Sync Pulse

In micro-EDM, the debris generated in machining process is difficult to be moved from the discharging gap, the discharge state is instability, and the material removal rate is low. A new method of PZT incentive synchronous compression discharge channel micro-EDM is presented based on the inverse piezoelectric effect of PZT piezoelectric ceramics, using a spark discharge and PZT sync pulse power. In this paper, the system composition and machining principles are described in detail, and its machining mechanism is analyzed in terms of the experiments. By the experiments, it is certificated that on the process of PZT sync compressing discharge channel machining, the state of discharge gap, the machining efficiency and quality can be improved, the throw out of debris makes easier, and then the stability of micro-EDM process is raised, which indicated that this new technology has wide application prospect in the field of micro manufacturing.

scholarly journals Cutting Parameter Optimization in Finishing Milling of Ti-6Al-4V Titanium Alloy under MQL Condition using TOPSIS and ANOVA Analysis

2021 ◽  
Vol 11 (1) ◽  
pp. 6775-6780
Author(s):  
V. C. Nguyen ◽  
T. D. Nguyen ◽  
D. H. Tien
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Contact Area ◽  
Removal Rate ◽  
Multiple Criteria Decision Making ◽  
Machining Process ◽  
Anova Analysis ◽  
Wide Range ◽  
Cutting Parameter Optimization

Titanium and its alloys give immense specific strength, imparting properties such as corrosion and fracture resistance, making them the right candidate for medical and aerospace applications. There is a wide range of engineering applications that use titanium alloys in a variety of forms. The cost of these alloys is slightly higher in comparison to other variants due to the problematic extraction of the molten process. To reduce costs, titanium alloy products could be made by casting, isothermal forging, radial swaging, or powder metallurgy, although these techniques require some kind of finishing machining process. Titanium and its alloys are difficult to machine due to skinny chips leading to a small cutting tool-workpiece contact area. The thermal conductivity of titanium alloys is too low and the stress produced is too large due to the small contact area, which results in very high cutting temperatures. This paper deals with the experimental study of the influence of the Minimum Quantity Lubricant (MQL) environment in the milling of Ti-6Al-4V alloy considering the optimization of surface roughness and production rate. Taguchi-based TOPSIS and ANOVA were used to analyze the results. The experimental results show that MQL with vegetable oil is successfully applied in the milling of Ti-6Al-4V. The research confirms the suitability of TOPSIS in solving the Multiple Criteria Decision Making (MCDM) issue, by choosing the best alternative at Vc=120m/min, fz=0.065mm/tooth, and ap=0.2mm, where the surface roughness and material removal rate are 0.41µm and 44.1492cm3/min respectively. Besides, ANOVA can be used to predict the best parameters set in the milling process based on the regression model. The parameters predicted by ANOVA analysis do not coincide with any implemented parameters

Fabrication of hydrophobic surfaces on Titanium using Micro-EDM exhibiting antibacterial properties

2021 ◽  
pp. 095440542110609
Author(s):  
Arjita Das ◽  
Shikha Ambastha ◽  
Nivedita Priyadarshni ◽  
Sudip Samanta ◽  
Nagahanumaiah
Keyword(s):  
Bacterial Growth ◽  
Bacterial Infections ◽  
Electrical Discharge Machining ◽  
Antibacterial Properties ◽  
Pure Titanium ◽  
Patterned Surfaces ◽  
Micro Edm ◽  
Patterned Surface ◽  
Micro Patterning ◽  
Cp Ti

Microbial contamination on medical assistive devices has been the major challenge for biomedical industries. The present work is focused on producing patterned surfaces on commercially pure Titanium (cp-Ti) using Micro-Electrical Discharge Machining (Micro-EDM) technique, and the feasibility of patterned surface in restricting bacterial growth. Geometrical patterning in form of micro-holes have been produced on cp-Ti biomaterials with Micro-EDM in two forms, one with 20 µm inter-distance forming a dense pattern and the other with 60 µm inter-distance forming a sparse pattern. The patterned surface establishes the degree of hydrophobicity as 130° and 106° for densely patterned and sparsely patterned surfaces respectively. Further, the effect of bacterial adhesion over the textured cp-Ti surfaces are challenged with model bacteria gram negative Escherichia coli (e.coli) in Luria broth (LB) agar media. The Colony Forming Unit (CFU) count obtained for densely patterned surface compared with that of non-patterned surface reflects 90% reduced bacterial growth. The instances of pattern formation and bacterial growth have been observed with Scanning Electron Microscopy. The enhanced material properties with micro-patterning that combat microbial activities on the biomaterial surface proves its efficacy in adoption for biomedical applications, with significant reduction in bacterial contamination on medical devices or implants, leading toward reduced healthcare risks and issues related to bacterial infections on the biomaterials.

Experimental Investigation of Abrasive Waterjet Machining of Titanium Graphite Laminates

2016 ◽  
Vol 10 (3) ◽  
pp. 392-400 ◽  
Author(s):  
M. Ramulu ◽  
◽  
Vara Isvilanonda ◽  
Rishi Pahuja ◽  
Mohamed Hashish ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Temperature ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Material System ◽  
Operating Variables

High temperature Fiber Metal Laminate – Titanium/Graphite (Ti/Gr) is an advanced material system, developed to meet the high temperature requirements in aerospace applications. High specific strength and stiffness of composite core along with its protection from aggressive environment by tough titanium alloy sheets qualify FMLs for a promising alternative material where metallic and composites overcome each other's limitations. However, industrial employability of this three phase system is often limited by the machining challenges posed by the difference in material removal mechanisms of Titanium alloy, PIXA thermoplastic polyimide resin and graphite fibers. An experimental investigation was conducted to evaluate the machinability of 1 mm thick Ti/Gr laminate sheets through Abrasive Waterjet (AWJ) machining process in terms of kerf characteristics and material removal rate. The parametric influence of AWJ operating variables on machining performance was studied by systematically measuring operating variables (traverse speed and Abrasive flow rate) using fully crossed Design of experiment (DOE) scheme, and statistically analyzing using ANOVA (Analysis of variance) technique. Empirical models were developed to quantify these effects and predict the influence of process parameters on material removal rate, kerf taper, entry damage width and overcut in straight cutting of Ti/Gr sheets.

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

Estimation of optimal cutting conditions during machining of CP-Ti grade 2 in fuzzy–VIKOR context

2020 ◽  
Vol 10 (3) ◽  
pp. 293-310 ◽  
Author(s):  
Akhtar Khan ◽  
Kalipada Maity
Keyword(s):  
Surface Finish ◽  
Pure Titanium ◽  
Cutting Conditions ◽  
Machining Process ◽  
Hybrid Technique ◽  
Commercially Pure Titanium ◽  
Content Type ◽  
Fuzzy Vikor ◽  
Commercially Pure ◽  
Cp Ti

PurposeTo explore a hybrid approach in order to attain optimal cutting conditions proficient of generating adequate dimensional accuracy in combination with virtuous surface finish during turning of commercially pure titanium (CP-Ti) grade 2.Design/methodology/approachIn the present paper, an application of the hybrid fuzzy–VIKOR method has been proposed to estimate an optimal combination of process variables during turning of commercially pure titanium (CP-Ti) grade 2. Three distinct input factors, namely, cutting speed, feed rate and depth of cut, were selected, each varied at three levels. Thus, a series of experiments were performed based on Taguchi's 3-factor-3-level (L27) orthogonal array. The major attention was given to acquire minimum cutting force and flank wear along with good surface finish. The adequacy of the proposed methodology was verified with the help of ANOVA test.FindingsThe results of the investigation revealed that the suggested hybrid technique is quite effective, easily understandable and time-saving approach, which can be successfully implemented to solve various problems either of similar or of different kinds.Originality/valueIncreasing demand of qualitative as well as low cost products is identified as the main challenging task in the current competitive market. Therefore, estimation and selection of the most suitable machining environment are of paramount importance in a real-time manufacturing system. Machining process involves both qualitative and quantitative factors, may be conflicting in nature, all to be considered together. Consequently, an appropriate combination of the machining variables is evidently desirable to meet the aforesaid challenges effectively.

A Study on the Die-Sinking Micro-Electrical Discharge Machining of EN-24 Die Steel Using Various Electrode Materials

2014 ◽  
Vol 984-985 ◽  
pp. 73-82 ◽  
Author(s):  
A. Kadirvel ◽  
P. Hariharan ◽  
M. Mudhukrishnan
Keyword(s):  
Surface Roughness ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Die Steel ◽  
Micro Holes

Micro-EDM is an extensively used machining process for the fabrication of micro-holes with various advantages resulting from its characteristics of non-contact and thermal process. In this micro-fabrication technique, processing parameters greatly affect processing efficiency and stability. An experimental investigation on die-sinking Micro-EDM of EN-24 die steel using various electrodes such as tungsten, copper, copper tungsten and silver tungsten has been carried out. The present study aims to assess the quality and accuracy of the produced micro-holes, machining stability, material removal rate (MRR), tool wear ratio (TWR), surface roughness (Ra), Heat affected zone (HAZ) and overcut (OC). In addition, the influence of gap voltage, capacitance and discharge energy on the performance of the process has also been investigated. Experimental results proved that the overall performance of the copper electrode is found to be optimum with high MRR, thin HAZ though copper shows higher TWR, surface roughness and overcut.

scholarly journals Enhancement of machinability of titanium alloy in the Eductor based PMEDM process

2021 ◽  
Vol 3 (4) ◽  
Author(s):  
S. Jeavudeen ◽  
H. Siddhi Jailani ◽  
M. Murugan
Keyword(s):  
Titanium Alloy ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
Powder Mixing ◽  
Dielectric Mixture ◽  
Confirmation Test ◽  
Delivery Pressure ◽  
Made In

AbstractIn this study, an attempt has been made in PMEDM process to sustain the homogeneity in the powder-dielectric mixture irrespective of the nature of the powders, their particle size, concentration etc., The traditional way of powder mixing system in Powder Mixing Electric Discharge Machining (PMEDM) has been refurbished with a novel Eductor based system along with a metering devise to ensure uniform mixing of the powers with the dielectric. Additionally sintered crucible filtration test on the sample of powder-dielectric mixture ensured the presence of known quantity of powders in the dielectric. The experiments are conducted on Titanium alloy with Gap current, Duty factor, Delivery pressure, powder types (Alumina, Silica, and copper) and concentration of these powders as variable process parameters. The output responses, namely material removal rate, tool wear index and surface finish obtained during the machining process have been optimized using AHP-TOPSIS method. The confirmation test indicated that the closeness co-efficient value for the TOPSIS analysis improved by 2.37% compared with the predicted value.

scholarly journals Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
T. Praveena Gopinath ◽  
J. Prasanna ◽  
C. Chandrasekhara Sastry ◽  
Sandeep Patil
Keyword(s):  
Magnetic Field ◽  
Titanium Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Micro Hole ◽  
Neodymium Magnets ◽  
Pulse On Time

Abstract An attempt has been made to study the influence of magnetic field on the micro hole machining of Ti-6Al-4V titanium alloy using electrochemical micromachining (ECMM) process. The presence of magneto hydro dynamics (MHD) is accomplished with the aid of external magnetic field (neodymium magnets) in order to improve the machining accuracy and the performance characteristics of ECMM. Close to ideal solution for magnetic and nonmagnetic field ECMM process, the parameters used are as follows: concentration electrolyte of 15 g/l; peak current of 1.35 A; pulse on time of 400 s; and duty factor of 0.5. An improvement of 11.91–52.43% and 23.51–129.68% in material removal rate (MRR) and 6.03–21.47% and 18.32–33.09% in overcut (OC) is observed in ECMM of titanium alloy under the influence of attraction and repulsion magnetic field, respectively, in correlation with nonmagnetic field ECMM process. A 55.34% surface roughness factor reduction is ascertained in the hole profile in magnetic field-ECMM in correlation with electrochemical machined titanium alloy under nonmagnetic field environment. No machining related stress is induced in the titanium alloy, even though environment of electrochemical machining process has been enhanced with the presence of magnetic field. A slight surge in the compressive residual factor, aids in surge of passivation potential of titanium alloy, resulting in higher resistance to outside environment.

Powder Mixed Micro Electro Discharge Milling of Titanium Alloy: Investigation of Material Removal Rate

2011 ◽  
Vol 383-390 ◽  
pp. 1759-1763 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Nur Atiqah Binti Abdul Rahman ◽  
Erniyati Binti Mohamad Aris
Keyword(s):  
Titanium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Optimum Level ◽  
Machining Parameters ◽  
Micro Edm ◽  
Discharge Energy ◽  
Powder Concentration

This paper presents effects of silicon carbide (SiC) powder in dielectric fluid of micro EDM on material removal rate (MRR). The aim is to identify the optimum level of SiC powder concentration and other micro EDM parameter for higher MRR. The work material was titanium alloy (Ti-6Al-4V) machined with tungsten carbide (WC) electrode by varying two machining parameters SiC powder concentrations and discharge energy. By using two factor four level factorial design of experiment, sixteen experiments were conducted. Data were analyzed by Design Expert® software. In this experimental investigation, maximum MRR of 7.3 µg/min was obtained for 24.75 g/l SiC powder concentration and 56.77 µJ discharge energy. The analysis of variance revealed that the SiC powder concentration in dielectric fluid on micro EDM has significant influence on MRR Ti-6Al-4V titanium alloy.

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