An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance

Paswan, Kamlesh; Pramanik, Alokesh; Chattopadhyaya, Somnath; Sharma, Shubham; Singh, Gurminder; Khan, Aqib Mashood; Singh, Sunpreet

doi:10.1007/s13369-023-07626-x

Cited by 10 publications

(3 citation statements)

References 52 publications

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“…A steeply inclined slope or curvature in the characteristic curve shows the input parameter factor as the response is sensitive to the output parameter surface roughness. As closeness to a flat line displays insensitivity to make a difference in that specific factor (Amoljit Paswan et al, 2023). Figure 5A illustrates the relationship among residuals and predicted values of surface roughness.…”

Section: Mathematical Modelling and Regression Analysismentioning

confidence: 99%

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

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Introduction: Among alloys of medium-carbon and high-strength steel, EN 24 steel is characterised by its nickel-chromium-molybdenum composition. EN 24 steel is highly suitable for application in heavy-duty projects due to its notable resilience to damage, especially when exposed to low temperatures. With the objective of minimising surface irregularities, this research endeavours to enhance the milling process of EN 24 steel by employing coated tungsten carbide (WC) tool inserts.Methods: Feed rate, cutting speed, depth of cut, and cutting fluid are all crucial process factors in the experimental investigation. Four distinct levels are applied to each factor. The research utilises the Design of Experiments (DOE)-based Central Composite Design of Response Surface Methodology. To predict output parameters, mathematical models are developed utilising analysis of variance (ANOVA) for optimisation purposes.Results and discussions: Through the utilisation of multi-objective optimisation, the optimal combination for tungsten carbide inserts was determined, which provided surface irregularities of 0.301 µm. Cutting speed (CS) of 149.507 m/min, feed rate (FR) of 340.27 mm/min, depth of cut (DOC) of 0.599 mm, and cutting fluid (CF) of 12.50 L/min are the optimal parameters. The surface morphologies of the machined workpiece at particular parameter values can be discerned through scanning electron microscope (SEM) analysis, yielding significant insights. The optimal parameters that have been identified provide practical recommendations for improving the milling method of EN 24 steel when tungsten carbide inserts are utilised. Understanding the milling process in its entirety is facilitated by SEM analysis of surface morphologies and microstructures under particular cutting conditions. The morphology and surface irregularities of the machined workpiece are evaluated using profilometry, which provides additional insight into surface integrity. The discourse investigates the potential applications and implications of the results, as well as suggests directions for further study concerning the enhancement of milling processes for similar steel alloys.

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Section: Mathematical Modelling and Regression Analysismentioning

confidence: 99%

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

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“…Rapid solidification hinders the molten metal from contracting, developing tension parallel to the surface of the machined workpiece and creating cracks within the surface. A component may fail as a consequence of these cracks because they reduce its fatigue and corrosion resistance [18]. Elevated temperature is generated near the machined surface because of the sparks.…”

Section: Parameters Affecting the Surface Crack Densitymentioning

confidence: 99%

Enhancing Electrical Discharge Machining Performance by Mixing Nano Chromium Trioxide Powder with Soybean Dielectric to Machine Inconel 718 Alloy

Ghulam,

Ibrahim

2024

Adv. Sci. Technol. Res. J.

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Inconel 718 super alloy is suitable for components exposed to high temperatures and demanding high strength; it is one of the hardest alloys to machine by conventional processes due to its properties. Nano Powder mixed electrical discharge machining is one of the most sophisticated processes to produce precise three dimensional complicated forms of hard metals through a thermo-physical process, so it is suitable for machining Inconel 718. This study reports an experimental investigation to improve the machining performance of Inconel 718 super alloy by adding nano chromium oxide powder particles to biodegradable and renewable soybean oil, which is used as a dielectric fluid to preserve the environment, with a magnetic field to assist in improving the process performance. The effects of machining parameters, namely peak current, pulse on time, powder concentration, and magnetic field on the responses in terms of white layer thickness, heat affected zone, surface roughness, material removal rate, and surface crack density were investigated. The observed results manifested that the addition of nano chromium oxide particles to dielectric fluid enhances the process performance. The white layer thickness and heat affected zone improved by 43.93% and 48.82%, respectively. The enhancements in measured surface roughness and material removal rate were 51.76% and 20.62%, respectively. Micrographs of scanning electron microscope verifies that the number of cracks on the machined surface with 4 g/l of nano Cr 2 O 3 powder addition was reduced by half, and surface crack density improved by 10.31%, in comparison to machining without powder addition. It is observed that the current had the largest effect on the responses, followed by powder concentration, pulse on time, and magnetic field.

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“…This versatility, combined with their favorable mechanical properties, has cemented aluminum alloys as a cornerstone material in modern engineering and manufacturing. Aluminum composite materials, often referred to as aluminum composites or ACMs, are engineered structures comprising layers of aluminum sheets bonded to a non-aluminum core material [8][9][10]. These composites combine the lightweight and corrosion-resistant properties of aluminum with the rigidity and strength of the core material, typically polyethylene (PE) or fire-retardant (FR) materials [11].ACMs offer a plethora of advantages, making them widely utilized in architecture, signage, transportation, and other industries [12][13].…”

Section: Introductionmentioning

confidence: 99%

Boron Nitride Reinforcement: Revolutionizing Aluminum-Based Composite Manufacturing via Friction Stir Process

Sharma,

Singh

et al. 2024

E3S Web of Conf.

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The revolutionizing potential of boron nitride (BN) reinforcement in Aluminum-Based Composite Manufacturing via Friction Stir Process (FSP) is showcased in this study. FSP, executed with precision using a vertical milling machine, fabricates composite materials with exceptional properties. The meticulous selection of parameters, including pin diameter, tool tilt angle, and rotation speed, ensures optimal results. AA 2024 substrate undergoes secure affixation, adhering to cleanliness protocols. The SEM image reveals a homogenous dispersion of BN particles, crucial for optimizing mechanical, thermal, and electrical properties.The incorporation of BN via FSP leads to significant enhancements across various mechanical properties. Tensile strength improves by 20.78%, hardness by 34.44%, fatigue strength by 23.83%, and wear resistance by 28.28%. These improvements underscore the efficacy of BN reinforcement through FSP, offering promising prospects for advanced composite manufacturing. The study exemplifies the potential of BN to revolutionize the industry, paving the way for the development of high-performance aluminum composites with superior mechanical characteristics.

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An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance

Cited by 10 publications

References 52 publications

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Enhancing Electrical Discharge Machining Performance by Mixing Nano Chromium Trioxide Powder with Soybean Dielectric to Machine Inconel 718 Alloy

Boron Nitride Reinforcement: Revolutionizing Aluminum-Based Composite Manufacturing via Friction Stir Process

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