A Novel Flushing Mechanism to Minimize Roughness and Dimensional Errors during Wire Electric Discharge Machining of Complex Profiles on Inconel 718

Farooq, Muhammad Umar; Anwar, Saqib; Kumar, M. Saravana; Alfaify, Abdullah; Ali, Mohammad; Kumar, Raman; Haber, Rodolfo E.

doi:10.3390/ma15207330

Cited by 23 publications

(12 citation statements)

References 37 publications

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“…Circularity error is the radial distance between the minimum circumscribing circle and the maximum inscribing circle, as shown in Figure 6 [ 42 , 43 ]. The quality of the hole in the case of Ti alloy remains good, while in the case of CFRP, delamination at the inlet is observed during the milling process [ 44 ].…”

Section: Resultsmentioning

confidence: 99%

“…The results of temperature rise are comparable to the values reported in the literature [ 55 , 56 ], even at low axial pitch in experimental work on helical milling of Ti. Increasing the concentration of nanoparticles in lubricant reduces the temperature as they help heat transfer [ 43 ]. Moreover, an increase in the spindle speed reflects an increase in temperature because of high cutting forces.…”

Section: Resultsmentioning

confidence: 99%

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Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Mughal

Farooq

et al. 2023

Materials

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The structural components in the aeronautical industry require CFRP/Ti6Al4V stacks to be processed together, which results in poor hole integrity due to the thermal properties of the materials and challenges related to processability. These challenges include quality variation of the machined holes because of the limitations in process properties. Therefore, a novel solution through helical milling is investigated in the study using nano fluid based minimum quantity lubrication (NF-MQL). The analysis of variance shows, for Ti6Al4V, eccentricity (PCR = 28.56%), spindle speed (Ti) (PCR = 42.84%), and tangential feed (PCR = 8.61%), and for CFRP, tangential feed (PCR = 40.16%), spindle speed (PCR = 28.75%), and eccentricity (PCR = 8.41%) are the most significant parameters for diametric error. Further on, the rise in the circularity error is observed because of prolonged tool engagement at a higher value of tangential feed. Moreover, the surface roughness of Ti was reduced with an increasing percentage of MoS2 in the lubricant. The spindle speed (37.37%) and lubricant (45.76%) have a potential influence on the processing temperature, as evident in the analysis of variance. Similarly, spindle speed Ti (61.16%), tangential feed (23.37%), and lubrication (11.32%) controlled flank wear, which is critical to tool life. Moreover, the concentration of MoS2 decreased edge wear from ~105 µm (0.5% concentration) to ~70 µm (1% concentration). Thorough analyses on process performance in terms of hole accuracy, surface roughness, processing temperature, and tool wear are carried out based on the physical science of the process for cleaner production. The NF-MQL has significantly improved process performance and hole integrity.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Mughal

Farooq

et al. 2023

Materials

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“…Moreover, the dielectric is supplied in the form of a stream along the electrode from both guides in order to cool and isolate the electrode and to rinse the working gap from erosion products. As an alternative, a novel flushing mechanism has been proposed in recent years, where the dielectric is supplied to the machining zone as a stream [ 102 , 103 , 104 ]. The machining process consists of material removal as a result of melting and evaporation due to electrical discharges between the tool and the workpiece [ 105 , 106 , 107 ].…”

Section: Methods Of Manufacturing Fir Tree Slots Of the Turbine Discsmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

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“… The innovative flushing mechanism implemented in the wire electro discharge machining (WEDM) by Farooq et al [ 67 ]. …”

Section: Figurementioning

confidence: 99%

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Pedroso,

Sebbe,

Silva

et al. 2024

Materials

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Build-up-edge (BUE), high-temperature machining and tool wear (TW) are some of the problems associated with difficult-to-machine materials for high-temperature applications, contributing significantly to high-cost manufacturing and poor tool life (TL) management. A detailed review of non-traditional machining processes that ease the machinability of INCONEL®, decrease manufacturing costs and suppress assembly complications is thus of paramount significance. Progress taken within the field of INCONEL® non-conventional processes from 2016 to 2023, the most recent solutions found in the industry, and the prospects from researchers have been analysed and presented. In ensuing research, it was quickly noticeable that some techniques are yet to be intensely exploited. Non-conventional INCONEL® machining processes have characteristics that can effectively increase the mechanical properties of the produced components without tool-workpiece contact, posing significant advantages over traditional manufacturing.

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A Novel Flushing Mechanism to Minimize Roughness and Dimensional Errors during Wire Electric Discharge Machining of Complex Profiles on Inconel 718

Cited by 23 publications

References 37 publications

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

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