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.

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.

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.

Effect of Arc Discharge Pressure on Discharge Current in EDM

2008 ◽  
Vol 381-382 ◽  
pp. 451-454
Author(s):  
Atsutoshi Hirao ◽  
S. Tai ◽  
H. Takezawa ◽  
Naotake Mohri ◽  
Kazuro Kageyama ◽  
...  
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Vibration Sensor ◽  
Work Piece ◽  
Tool Electrode ◽  
Discharge Pressure ◽  
Current Behavior

In electrical discharge machining (EDM), an electrical discharge occurs between a tool electrode and a work-piece, and removal of materials is carried out by vaporized explosion between the electrode and the work-piece. However, the mechanism of material removal in EDM is not well understood. In order to clarify this issue, the acoustic emission (AE) method has been applied to examine the force of explosion, and the Schlieren visualization method has been applied to observe the explosion. In this study, we investigate the effect of discharge current behavior on the occurrence of the AE waves by means of an optical fiber vibration sensor.

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.

Small Diameter External Cylindrical Surfaces Obtained by Ram Electrical Discharge Machining

2014 ◽  
Vol 611-612 ◽  
pp. 650-655 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Irina Besliu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Analysis ◽  
Electrical Discharge Machine ◽  
Small Diameter ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Electrical Discharges ◽  
Pulse On Time

Electrical discharge machining uses the pulse electrical discharges generated between the closest asperities existing on the workpiece surface and the active surface of the tool electrode in dielectric fluid. Essentially, some distinct electrical discharge machining schemas could be used in order to obtain cylindrical external surfaces; within this research, one preferred a machining schema based on the use of a cooper plate in which there were small diameter holes, by taking into consideration the existence of a ram electrical discharge machine. The results of the machining process analysis were presented. A thin copper was considered to be used as tool electrode, in order to diminish the spurious electrical discharges, able to generate shape errors of the machined surface. Some experimental researches were developed by changing the sizes of the process input parameters. As output factors, the test piece and tool electrode masses decreases were considered. Power type empirical mathematical models were determined, in order to highlight the influence exerted by the pulse on time, off time and machining process duration on the output parameters values.

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).

A DoE–TOPSIS method-based meta-model for parametric optimization of non-traditional machining processes

2019 ◽  
Vol 14 (2) ◽  
pp. 430-455 ◽  
Author(s):  
Shankar Chakraborty ◽  
Prasenjit Chatterjee ◽  
Partha Protim Das
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Topsis Method ◽  
Machining Performance ◽  
Machining Processes ◽  
Inconel 718 Alloy ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

PurposeTo meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional machining (NTM) processes have now become quite popular in manufacturing industries. To explore the fullest machining capability of these NTM processes, it is often required to operate them while setting their different controllable parameters at optimal levels. This paper aims to present a novel approach for selection of the optimal parametric mixes for different NTM processes in order to assist the concerned process engineers.Design/methodology/approachIn this paper, design of experiments (DoE) and technique for order preference by similarity to ideal solution (TOPSIS) are combined to develop the corresponding meta-models for identifying the optimal parametric combinations of two NTM processes, i.e. electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) processes with respect to the computed TOPSIS scores.FindingsFor EDM operation on Inconel 718 alloy, lower settings of open circuit voltage and pulse-on time and higher settings of peak current, duty factor and flushing pressure will simultaneously optimize all the six responses. On the other hand, for the WEDM process, the best machining performance can be expected to occur at a parametric combination of zinc-coated wire, lower settings of pulse-on time, wire feed rate and sensitivity and intermediate setting of pulse-off time.Practical implicationsAs the development of these meta-models is based on the analysis of the experimental data, they are expected to be more practical, being immune to the introduction of additional parameters in the analysis. It is also observed that the derived optimal parametric settings would provide better values of the considered responses as compared to those already determined by past researchers.Originality/valueThis DoE–TOPSIS method-based approach can be applied to varieties of NTM as well as conventional machining processes to determine the optimal parametric combinations for having their improved machining performance.

A Comparative Study of EDD and PM-EDD in Producing Holes in Inconel 718 Alloy

2020 ◽  
Vol 833 ◽  
pp. 48-53
Author(s):  
Rahul Davis ◽  
Abhishek Singh ◽  
Sabindra Kachhap ◽  
Neeraj Nath
Keyword(s):  
Thermal Conductivity ◽  
Comparative Study ◽  
Electric Discharge ◽  
Inconel 718 ◽  
Elevated Temperatures ◽  
Removal Rate ◽  
Chemical Properties ◽  
Tool Electrode ◽  
Inconel 718 Alloy ◽  
Pulse On Time

In recent times, aerospace, chemical industries and nuclear plant have usually used Inconel 718 alloy because of its excellent mechanical and chemical properties at elevated temperatures. It falls under the category of difficult-to-cut materials due to its high toughness, poor thermal conductivity and high hardness. The set-ups for electric discharge drilling (EDD) and powder-mixed electric discharge drilling (PM-EDD) were developed, and experiments were conducted on them separately. This research shows a comparative study amid producing holes by EDD and PM-EDD in Inconel 718 alloy workpiece with copper tool electrode. SiC was used as an abrasive powder because of its better thermal conductivity in order to get properly mixed with dielectric in a separate tank. Output response was assessed in the form of material removal rate, under the influence of discharge current, duty factor, pulse-on-time and tool speed, as the input parameters.

Experimental Investigation and Optimization of Process Parameter for Inconel 718 Using Wire Electrical Discharge Machining

2019 ◽  
Vol 18 (03) ◽  
pp. 339-362 ◽  
Author(s):  
Anshuman Kumar ◽  
K. Vivekananda ◽  
Kumar Abhishek
Keyword(s):  
Experimental Investigation ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Parameter ◽  
Pareto Optimal ◽  
Wire Electrical Discharge Machining ◽  
Nsga Ii ◽  
Pulse On Time ◽  
Optimal Set

Inconel 718 is a nickel-based superalloy having high strength and low thermal conductivity. Due to its properties, wire electrical discharge machining has been selected. The paper reports an experimental investigation of Inconel 718 using zinc-coated brass wire electrode. Based on [Formula: see text], Box-Behnken design of response surface methodology has been adopted to estimate the effect of process parameter on the machining responses. Four controllable process parameters (viz., wire tension, wire speed, discharge current and pulse-on time) vary, each at three discrete levels, between parametric domains. The following machining responses, in terms of material removal rate (MRR), surface roughness ([Formula: see text]) and corner deviation ([Formula: see text]), have been investigated. Finally, an evolutionary computation method has been used based on non-dominated sorting genetic algorithm (NSGA-II) in order to find out the optimal set of solutions for rough-cutting. Experimental data have been used to develop regression models to optimize the process. The adequacy of the developed mathematical model has also been tested by the analysis of variance results. Pareto-optimal settings obtained through NSGA-II have been ranked by gray relation analysis to identify the best optimal set of solutions to avoid lengthiness and impreciseness in the judgment. Confirmation tests have been conducted for optimum machining parameter from the set of Pareto-optimal solutions for proving betterment.

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.

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