scholarly journals Analysis of control factors and surface integrity during wire-EDM of Inconel 718 alloy using T-GRA approach

2021 ◽  
Vol 9 (2) ◽  
pp. 294-312
Author(s):  
Md Ehsan Asgar ◽  
Ajay Kumar Singh Singholi
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse Interval ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Sem Images ◽  
Control Factors ◽  
Controllable Factors ◽  
Four Levels

In today’s competitive modern manufacturing sectors, there is a vital need of utter precision and rigorous processing using various manufacturing approaches that directly influences the cost and processing duration of mechanized materials in addition to the consistency of the finished products. Therefore, it’s essential to figure out the required output by adjusting the control factors of any machining techniques which resulted in optimal values of the desired outcome. In this study, machining evaluation and process optimization is carried out on volumetric extraction of material namely material removal rate (MRR), kerf obtained during the machining (KW) and surface roughness (SR) of Inconel 718 superalloy during CNC controlled wire- electrical discharge machining. Four controllable factors- pulse interval, wire speed, pulse duration and peak current are considered to investigate the influence on performance measures. Taguchi's L16 has been used to construct the set of experiments before physical experimental runs and most influencing factors have been evaluated using ANOVA. SEM images and EDXS analysis have been resorted to examine the morphology of Inconel 718. These findings assist in identifying the topography of the machined surface. Further, the optimum integration has been obtained for the best yield and recorded using grey relational analysis integrated with Taguchi’s technique (T-GRA). The unfamiliarity of the work is based on consideration of zinc coated thin wire electrode and Taguchi-Grey combined approach of modelling with four levels of experimental design.

Evaluation of Surface Quality during Electrical Discharge Machining of Inconel 718 with Powder Metallurgy Electrodes

2011 ◽  
Vol 410 ◽  
pp. 245-248 ◽  
Author(s):  
Naveen Beri ◽  
S. Maheshwari ◽  
C. Sharma
Keyword(s):  
Powder Metallurgy ◽  
Surface Quality ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Evaluation Criteria ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Energy Dispersion Spectrum ◽  
Pulse On Time

In recent years, researchers have reported powder metallurgy processed electrodes as alternative tooling for electrical discharge machining (EDM). The present experimental study evaluates the quality of machined surface during electrical discharge machining (EDM) of Inconel 718 alloy steel with powder metallurgy (PM) processed electrodes. The investigated process parameters were polarity, electrode type, peek current, pulse on time, duty cycle, gap voltage, retract distance and flushing pressure. The surface quality was measured in terms of surface roughness (Ra). An orthogonal array L36 (21X 37) based on Taguchi methodology was applied to plan and design experiments. Experimental data was statistically analyzed using analysis of variance (ANOVA) and optimum condition was achieved for evaluation criteria. It was concluded that polarity, electrode type, peek current, have significant effect on surface quality and minimum Ra is obtained with CuW2080 electrode at minimum current and negative polarity. Deposition of tungsten with CuW2080 (80%W 20%Cu) electrode was confirmed by energy dispersion spectrum (EDS) of the machined surface.

scholarly journals Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

2021 ◽  
Vol 67 (6) ◽  
Author(s):  
Boopathi Sampath ◽  
Sureshkumar Myilsamy
Keyword(s):  
Flow Rate ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Response Surfaces ◽  
Machining Process ◽  
Pulse Interval ◽  
Inconel 718 Alloy ◽  
The Wire

In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

scholarly journals Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

2021 ◽  
Vol 67 (6) ◽  
Author(s):  
Boopathi Sampath ◽  
Sureshkumar Myilsamy
Keyword(s):  
Flow Rate ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Response Surfaces ◽  
Machining Process ◽  
Pulse Interval ◽  
Inconel 718 Alloy ◽  
The Wire

In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

Some Preliminary Experimental Investigations on Inconel-718 Alloy with Rotary Tool-Electrode Assisted EDM

2019 ◽  
Vol 969 ◽  
pp. 650-655
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Experimental Investigations ◽  
Tool Electrode ◽  
Machining Performance ◽  
Inconel 718 Alloy ◽  
Study Results ◽  
Pulse On Time ◽  
Tool Rotation

In this paper, some preliminary experimental investigations have been reported for analysing the machining performance characteristics viz. Material Removal Rate (MRR) & Tool Wear Rate (TWR). Electrical Discharge Machining (EDM) of Inconel-718 alloy via helical threaded cryogenically treated rotary copper tool electrode is conducted. Impact of machining factors viz. peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were investigated using Taguchi’s L9 (34) Orthogonal Array (OA). Optimum arrangements of factors for greatest MRR & least TWR were found in current study. Results predicts that Ip & Nt are two most affecting machining factors that affects MRR. Whereas Ip & Ton are two most affecting machining factors that affects TWR.

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 An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6074
Author(s):  
Tingting Ni ◽  
Qingyu Liu ◽  
Zhiheng Chen ◽  
Dongsheng Jiang ◽  
Shufeng Sun
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Deionized Water ◽  
Micro Edm ◽  
Nano Particle ◽  
Machining Performance ◽  
Machined Surface ◽  
Micro Electrical Discharge Machining ◽  
Lower Tool

Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

EXPERIMENTAL INVESTIGATION OF MICRO-EDM OPERATION IN INCONEL 718

2021 ◽  
pp. 2150102
Author(s):  
MAYANK CHOUBEY ◽  
K. P. MAITY
Keyword(s):  
Experimental Investigation ◽  
Inconel 718 ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Machining Processes ◽  
Machining Time ◽  
Machine Material ◽  
Micro Holes ◽  
Unconventional Machining

The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.

A Multiobjective Genetic-Algorithm-Based Optimization of Micro-Electrical Discharge Drilling

2021 ◽  
pp. 676-698
Author(s):  
Deepak Rajendra Unune ◽  
Amit Aherwar
Keyword(s):  
Genetic Algorithm ◽  
Process Parameters ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining ◽  
Electrical Discharge Drilling ◽  
Machining Rate

Inconel 718 superalloy finds wide range of applications in various industries due to its superior mechanical properties including high strength, high hardness, resistance to corrosion, etc. Though poor machinability especially in micro-domain by conventional machining processes makes it one of the “difficult-to-cut” material. The micro-electrical discharge machining (µ-EDM) is appropriate process for machining any conductive material, although selection of machining parameters for higher machining rate and accuracy is difficult task. The present study attempts to optimize parameters in micro-electrical discharge drilling (µ-EDD) of Inconel 718. The material removal rate, electrode wear ratio, overcut, and taper angle have been selected as performance measures while gap voltage, capacitance, electrode rotational speed, and feed rate have been selected as process parameters. The optimum setting of process parameters has been obtained using Genetic Algorithm based multi-objective optimization and verified experimentally.

scholarly journals Enhancement of the Localization Effect during Electrochemical Machining of Inconel 718 by Using an Alkaline Solution

2019 ◽  
Vol 9 (4) ◽  
pp. 690 ◽  
Author(s):  
Dengyong Wang ◽  
Bin He ◽  
Wenjian Cao
Keyword(s):  
Alkaline Solution ◽  
Inconel 718 ◽  
Electrochemical Machining ◽  
Cost Effective ◽  
Machining Accuracy ◽  
Mixed Solution ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Localization Effect ◽  
Cost Effective Method

Electrochemical machining (ECM) is a cost-effective method for the machining of difficult-to-cut Inconel 718 superalloy. However, the machining accuracy of ECM is still limited by the poor localization effect due to the existence of stray corrosion. In this paper, a mixed solution of neutral NaNO3 and alkaline NaOH is used to improve the localization effect during ECM of Inconel 718. The potentiodynamic polarization curves and current efficiencies for metal dissolution are measured, and the micro morphologies are examined. The results show that the use of an alkaline solution can promote the formation of a compact passive film on the surface of Inconel 718. ECM tests with cylindrical electrodes are specially designed to verify the effect of alkaline solution on the localization of anodic dissolution. The experimental results indicated that the stray corrosion of the non-machined surface of Inconel 718 alloy can be effectively eliminated by using a mixed solution of NaNO3 and NaOH. The surface roughness of the non-machined area can be noticeably improved.

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.

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