scholarly journals Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1476 ◽  
Author(s):  
Magdalena Machno ◽  
Rafał Bogucki ◽  
Maciej Szkoda ◽  
Wojciech Bizoń
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Initial Temperature ◽  
Deionized Water ◽  
Working Fluid ◽  
Inconel 718 Alloy ◽  
Electrical Discharge Drilling ◽  
Side Gap

Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of the most effective methods of making high-aspect-ratio holes is electrical discharge drilling (EDD). While drilling high aspect ratio holes, a crucial issue is the flushing of the gap area and the evacuation of the erosion products. The use of deionized water as the dielectric fluid in the EDD offers a considerable potential. This paper includes an analysis of the influence of the machining parameters (pulse time, current amplitude and discharge voltage) on the process performance (drilling speed, linear tool wear, taper angle, hole’s aspect ratio, side gap thickness), during the EDD with the use of deionized water in the Inconel 718 alloy. The obtained through holes were subjected to the extended analysis. The impact of the initial working fluid temperature and pressure on the conditions of the flow through the electrode channel was also subjected to the analysis. The deionized water properties were changed by applying an initial temperature. Based on the results of an analysis of the previous research, the EDD of the through holes was performed for a pre-set initial temperature (~313.15 °K) and initial pressure of the working fluid (8 MPa) and selected process parameters. An analysis of the results indicates increasing of hole’s aspect ratio by about 15% (above 30), decreasing the side gap thickness by about 40% and enhanced surface integrity.

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.

Analysis of Surface Texture of High Aspect Ratio Blind Micro Holes on Titanium Alloy (Ti-6Al-4V) in Micro Electrical Discharge Drilling

2017 ◽  
Vol 261 ◽  
pp. 151-158 ◽  
Author(s):  
Swapan Barman ◽  
Asit Baran Puri ◽  
Nagahanumaiah
Keyword(s):  
Titanium Alloy ◽  
Aspect Ratio ◽  
Surface Integrity ◽  
High Aspect Ratio ◽  
Electrical Discharge ◽  
Desirability Function ◽  
Machining Process ◽  
Machining Parameters ◽  
Micro Holes ◽  
Electrical Discharge Drilling

Efficiency of any machining process depends on the effectiveness of final outcomes. Surface integrity plays an important role in functional performance of a part or component. Traditionally, surface roughness is considered to be the principal parameter to assess the surface integrity of a machined surface. In this paper, the influences of machining parameters like gap voltage, capacitance and depth of hole on the surface finish parameters like Ra and Sa of micro holes have been studied in micro electrical discharge drilling. The high aspect ratio blind micro holes were drilled on titanium alloy (Ti-6Al-4V) with cylindrical tungsten tool electrodes. The experimentation was carried out adopting a full factorial design (33). The simultaneous effects of machining parameters on responses were analysed using response surface methodology. Multiple linear regression models were developed for responses to obtain the correlation between machining parameters and machining outputs. Multi-objective optimization has been performed with the aid of the desirability function approach.

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 The Capabilities of Electrodischarge Microdrilling of High Aspect Ratio Holes in Ceramic Materials

2015 ◽  
Vol 6 (3) ◽  
pp. 61-69 ◽  
Author(s):  
Sebastian Skoczypiec ◽  
Magdalena Machno ◽  
Wojciech Bizoń
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
High Efficiency ◽  
Ceramic Materials ◽  
Good Alternative ◽  
Discharge Voltage ◽  
Drilling Speed ◽  
Electrically Conductive ◽  
Side Gap ◽  
The Impact

Abstract In the first part of the article the review of ceramic materials drilling possibilities was presented. Among the described methods special attention is paid to electrodischarge drilling. This process have especially been predicted for machining difficult-to-cut electrically conductive materials. The second part consist of the results analysis of electrodischarge microdrilling of siliconized silicon carbide. The experiment involves the impact of current amplitude, discharge voltage and pulse time on the hole depth, side gap, linear tool wear and mean drilling speed. The results shows that electrodischarge drilling is a good alternative when machining inhomogeneous ceramic materials and gives possibility to drill high aspect ratio holes with relatively high efficiency (the drilling speed >2 mm/min).

The Effects of Resharpening Accuracy on Drill Failure and Hole Straightness in High Aspect Ratio Gundrilling of Inconel-718

2012 ◽  
Vol 565 ◽  
pp. 388-393
Author(s):  
Keng Soon Woon ◽  
Shigeyuki Kanno ◽  
Kui Liu
Keyword(s):  
Pilot Study ◽  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Inconel 718 ◽  
Failure Modes ◽  
Drilling Process ◽  
The Stability ◽  
Drilling Conditions ◽  
High Degree

This paper presents a pilot study on the consistency of high aspect ratio gundrilling of Inconel-718 that involves the drilling of three holes of 8mm in diameter and 1600mm in depth, under constant drilling conditions. But high degree of straightness variations among these holes indicates that critical drill geometries could not be accurately regenerated through the drill resharpening operation. As a result, vast variability is introduced to the process which has severe detrimental effects on the stability of the drilling process and degradation and failure modes of the drill as well the straightness accuracy of the holes.

scholarly journals The influence of electrode infeed in finishing wire electrical discharge machining process on disks fir tree slot accuracy

Mechanik ◽  
2018 ◽  
Vol 91 (10) ◽  
pp. 915-917
Author(s):  
Jan Burek ◽  
Robert Babiarz ◽  
Marcin Płodzień ◽  
Jarosław Buk
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Inconel 718 Alloy ◽  
Shape Accuracy ◽  
Finishing Machining

The article presents the effect of electrode infeed in finishing machining of disk fir tree slots made of Inconel 718 alloy on shape accuracy and surface roughness in WEDM (wire electrical discharge machining).

scholarly journals On the Influence of Electrical Discharge Drilling Parameters and Per-formance Measures of Inconel 718 Superalloy - a Study

Mechanika ◽  
2021 ◽  
Vol 27 (6) ◽  
pp. 483-491
Author(s):  
Jayaraj JEEVAMALAR ◽  
Sundaresan RAMABALAN ◽  
Jayaraj JANCIRANI
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Removal Rate ◽  
Experimental Results ◽  
Drilling Process ◽  
Machining Parameters ◽  
Characteristic Analysis ◽  
Peak Current ◽  
Electrical Discharge Drilling ◽  
The Impact

In order to achieve higher productivity and product quality, the investigation of machining parameters on Electrical Discharge Drilling and surface characteristic analysis are most critical for manufacturing industries. The intention of this article is to assess the impact on performance matrices including Material Removal Rate, and Surface Roughness of input factors of peak current, pulse-on and off duration while drilling with a rotary hollow copper tool on Inconel 718 under Tungsten powder suspended kerosene. Analysis of Variance has been implemented using MINITAB release 18 software to identify the most significant input factors. An Artificial Neural Network was used for validating the experimental results of the drilling process. The additional intention of this research is to discover the significance of influencing input parameters and analyze the quality surface of the workpiece were observed by microscope tests. The experimental results indicated that the peak current and pulse-on period have an effect on the performance of the drilling process considerably.

The Plasma-Side Wall Interactions During Femtosecond Laser Drilling of High-Aspect-Ratio Microholes

2010 ◽  
Author(s):  
Benxin Wu ◽  
Sha Tao ◽  
Shuting Lei
Keyword(s):  
Aspect Ratio ◽  
Femtosecond Laser ◽  
High Aspect Ratio ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Side Wall ◽  
Femtosecond Laser Ablation ◽  
Laser Induced Plasma ◽  
Wall Interaction ◽  
Mechanical Machining

The drilling of high-aspect-ratio microholes has very important applications in automotive, aerospace, electronics and other areas. However, this is difficult to realize with conventional mechanical machining or electrical discharge machining approaches. Femtosecond laser ablation can potentially provide a good solution to this, but it also involves many technical difficulties. One of these is that the laser-induced plasma, as it expands out of the microhole, may transfer its energy to the side wall of the hole, which may affect the hole size and geometry. In this paper, the plasma – side wall interaction has been studied using a physics-based model, and the discovered characteristics of the interaction are discussed.

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