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.

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.

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.

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

Effect of Process Parameters in Electric Discharge Machining of Ti-6Al–4V Alloy by Three Different Tool Electrode Materials

2012 ◽  
Vol 488-489 ◽  
pp. 876-880 ◽  
Author(s):  
Manoj Kumar Kuttuboina ◽  
A. Uthirapathi ◽  
Singaravelu D. Lenin
Keyword(s):  
Process Parameters ◽  
Electrode Material ◽  
Electrode Materials ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Good Surface ◽  
Pulse On Time

The effect of process parameters namely peak current, pulse on time and flushing pressure on electrical discharge machining (EDM) of titanium alloy (Ti–6Al–4V) were investigated by using three different tool electrode materials namely copper, brass, and aluminium. Kerosene is used as dielectric. The process parameters for machining Ti6Al4V are varied at three levels by using Taguchi's orthogonal array table. The responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) are measured and the most significant parameter was confirmed by ANOVA (Analysis Of Variance). The test result shows that copper electrode material possesses higher MRR, less TWR as compared to brass and aluminium. Brass and copper tools has good surface finish as compared with aluminium. The finest electrode material for machining of Ti6Al4V alpha beta alloy in EDM process was in the order of copper, brass and aluminium.

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.

Technological Innovations in Machining of Inconel 718

2015 ◽  
Vol 5 (2) ◽  
pp. 17-43
Author(s):  
Vivek Aggarwal ◽  
Rajiv K Garg ◽  
Sehijpal Singh Khangura
Keyword(s):  
Inconel 718 ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Machining Performance ◽  
Drilling Operations ◽  
Machining Operations ◽  
Alternative Energies ◽  
Insight Into

In this paper, a thorough review has been presented on the latest research work carried out for the enhancement of machining performance of one of the most commonly used superalloys that is, Inconel 718. The thermal energy has been frequently utilized for improving machinability characteristics of Inconel 718. The review of available literature indicates that plasma, laser, and electric discharge have been the major sources used for the enhancement of tool life, material removal rate, surface integrity, and reduction of cutting forces during machining of Inconel 718. However, a very few efforts have been made as regards to the use of wire electrical discharge machining and other energies like mechanical, electrochemical, and chemical for machining of this material. Moreover, the reported work on machining of Inconel 718 is largely focused on drilling operations. There is ample scope for research work on various other machining operations using alternative energies to gain more insight into machining of Inconel 718 and other similar superalloys.

Optimization of Electrical Discharge Machining Process Parameters Using Desirability Approach

2012 ◽  
Vol 159 ◽  
pp. 176-180 ◽  
Author(s):  
P. Sengottuvel ◽  
S. Satish Kumar ◽  
D. Dinakaran
Keyword(s):  
Inconel 718 ◽  
Elevated Temperatures ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Nickel Content ◽  
Machining Process ◽  
Tool Geometry ◽  
Dielectric Fluid ◽  
Desirability Approach ◽  
Pulse On Time

Inconel 718 is a high nickel content super alloy having high strength at elevated temperatures and resistance to oxidation and corrosion. EDM process has many advantages over traditional manufacturing process during the machining of inconel 718. In this study experiments were conducted based on the L16 orthogonal array on inconel 718 material using tungsten-carbide (W-C) electrode tool material with kerosene as a dielectric fluid to determine the optimum EDM parameters along with circle(C), square(S), rectangle(R) and triangle (T) tool geometry which contribute to material removal rate (MRR), tool wear rate (TWR) &surface roughness (SR) in machining of inconel 718. Data were optimized using Desirability approach technique. Experimental results show that the current and pulse on time are most influencing parameters that are directly proportional to MRR and inversely proportional to TWR, SR. The rectangle tool geometry gave better results compared to other geometry

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

Improve the Surface Characteristics of the Electric Discharge Machining Employing a Method Burnishing Process

2020 ◽  
Vol 38 (4A) ◽  
pp. 545-551
Author(s):  
Shukry Aghdeab ◽  
Ahmed G. Abdulameer ◽  
Ahmed B. Abdulwahhab ◽  
Majid H. Ismiel
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Tool Electrode ◽  
Internal Factors ◽  
Burnishing Process ◽  
Time Optimal ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical Discharge Machining (EDM) applies the concept of material eradication by utilizing electric spark erosion. The target of this exploration concentrates to examine the ideal procedure parameters of EDM on Aluminum 6061-T6as a workpiece with copper as a tool electrode. The effect of various process operators 'on machining rendering was examined. Internal factors with current (10, 20, 30) Ampere,  pulse on time (50, 100, 150) µs was used after which takes pulse off time (25, 50, 75) µs. All parameters applied for empirical acts with influence on Ra (surface roughness ).  The result showed that MRR" Material Removal Rate” is increment by expanding in current and pulse on time and it declines by expanding in pulse off time. Optimal condition are gained when using " Using current 30 Ampere, pulse on time is 150 µs and minimize assessment of pulse off time is 25 µs.

Effect of Wire Materials on Cutting Performance of WEDM for Machining of Inconel Superalloy

2014 ◽  
Vol 624 ◽  
pp. 124-128 ◽  
Author(s):  
Rajiv Kumar Garg ◽  
Vivek Aggarwal ◽  
Sehijpal Singh
Keyword(s):  
Material Removal Rate ◽  
Inconel 718 ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Inconel 718 Superalloy ◽  
Important Input ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Brass Wire

The machining of superalloys has put really a challenge for technologists and researchers. The conventional techniques of machining do not give satisfactory performance for machining of superalloys. In this paper, the results of an experimental study for cutting of Inconel 718 superalloy with wire electrical discharge machining (WEDM) have been presented. Three different wire materials along with important input process parameters namely peak current, servo voltage, pulse on time and pulse off time have been selected. The effect of these parameters on material removal rate has been investigated by using well know experimental technique called response surface methodology. The experimental results indicate that zinc-coated brass wire is most suitable for Inconel 718. An empirical model has been developed for correlating input parameters and material removal rate for zinc-coated brass wire. Analysis of variance has also been presented.

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