Assessing the Effect of Nonelectrical Process Parameters During the Sted of Holes on Inconel 718 Alloy

Vats, Anuj; Ramver,; Dvivedi, Akshay; Kumar, Pradeep

doi:10.1201/9781003284024-32

Modern Manufacturing Systems 2022

DOI: 10.1201/9781003284024-32

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Assessing the Effect of Nonelectrical Process Parameters During the Sted of Holes on Inconel 718 Alloy

Anuj Vats¹,

Ramver Ramver²,

Akshay Dvivedi³

et al.

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“…5 Vats et al observed that the obstruction of electrolyte flow at high depths due to improper flushing while using a micro-tool makes sustaining the STED process problematic and limits the achievable TFR. 6 Further, the fabrication requirements in the micro-domain restrict the unjust overcutting, permitting a small side gap to remove residues of anodic dissolution from the IEG. Bilgi et al noticed that in the case of improper flushing when the sludge stays in the IEG, it leads to tool retraction and short-circuiting instances due to collisions between the tool and the work sample.…”

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confidence: 99%

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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Shaped tube electrolytic drilling (STED) is an electrochemical machining variant that employs a tubular tool electrode to produce holes with a high aspect ratio on hard-to-machine materials. The tubular electrodes with a diameter below 1 mm produce undesired residue (center-peak) at the machining surface that hampers the machining rate. Therefore, this study attempts to improve the electrolyte flow and enhance the electrochemical dissolution through tool modification. The performance enhancement of the STED process in terms of material removal rate and average diametral overcut has been explored. The issues related to the limitations in material removal in the STED process are brought forth with the technique to resolve those difficulties. The experiments were conducted with the modified tubular tool, and the length of slits on the tool was selected based on the simulation insights and pilot study. The effects of input process parameters (applied voltage, tool feed rate, electrolyte concentration, and tool slit length) on the output responses obtained from the STED process are elaborated. Holes with diameters in the range 0.89-0.97 mm and 12 mm depth were fabricated. Further optimization of the process parameters in the design space is also presented to obtain sustainable process performance.

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confidence: 99%

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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“…Surface topography during the STEM process hinges on a multitude of influential process parameters. 13 all playing a pivotal function in influencing it. 14 Zhu et al 15 studied the effect having different microstructures of Inconel 718 work material on the surface roughness during ECM.…”

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confidence: 99%

Enhancing Surface Integrity of Micro-Holes Machined on Inconel 718 using Shaped Tube Electrochemical Machining via Hydroxide Mixing

Vats,

Singh,

Dvivedi

et al. 2023

J. Electrochem. Soc.

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This research explores enhancing surface integrity of high aspect ratio (AR>5) micro-holes machined on Inconel 718 using Shaped Tube Electrochemical Machining (STEM) by mixing limited amount of metal hydroxides in the different electrolyte solutions. Typically, STEM employs hazardous acid solutions. These solutions cause machine corrosion, environmental risks, and harm to operators. This research aims to explore eco-friendly and safe alternatives. The efficacy of adding NaOH or KOH to eco-friendly neutral aqueous solutions of NaCl, KBr, and NaNO3 on machined surfaces is expounded. We assess electrolyte mixing parameters, including concentration and composition, and explore the effects of varying electrolyte temperature, voltage, and tool feed rate. Surface assessment uses SEM, EDX, XRD, and profilometry. Results reveal that adding hydroxides to neutral salt solutions improves surface roughness and reduces pitting. Hydroxide ions aid in dissolving oxide films during STEM of Inconel 718. Under specific conditions (9 g l−1, 18°C, 8 V, 0.8 mm min−1), NO3│OH yielded the lowest Ra (1.64 μm), while Br│OH resulted in the highest Ra (2.14 μm) with pitting, cracks, and deposits. NO3│OH exhibited a 25% decrease in Ra when a hydroxide concentration rise from 3 g l−1 to 15 g l−1. This research supports eco-friendly STEM for improved surface quality without process performance compromise.

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Assessing the Effect of Nonelectrical Process Parameters During the Sted of Holes on Inconel 718 Alloy

Cited by 2 publications

References 0 publications

On Performance Enhancement of the STED Process Using Modified Tool Electrode

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Enhancing Surface Integrity of Micro-Holes Machined on Inconel 718 using Shaped Tube Electrochemical Machining via Hydroxide Mixing

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