EDM of Ti6Al4V under nano-graphene mixed dielectric: a detailed roughness analysis

Ishfaq, Kashif; Maqsood, Muhammad Asad; Anwar, Saqib; Harris, Muhammad; Alfaify, Abdullah; Zia, Abdul Wasy

doi:10.1007/s00170-022-09207-y

Cited by 28 publications

(9 citation statements)

References 33 publications

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“…At positive polarity, without mixing particles in the dielectric fluid, a TWR of 0.020 mg/min was observed and it was reduced to 0.017 mg/ min when electrodes were connected to negative polarity as depicted in Figure 5. In particle mixed dielectric condition, change in polarity has no impact on the TWR which is evident that incorporation of particles transfers more volume of heat to workpiece [29]. When the current was tuned at lower parametric value, the TWR increases when there is changeover in polarity from positive to negative extreme, and at higher current, TWR reduces with change in polarity.…”

Section: Resultsmentioning

confidence: 96%

Improving Sustainability of EDM Sector by Implementing Unconventional Competitive Manufacturing Approach

Anjani²,

Raman

et al. 2022

Advances in Materials Science and Engineering

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In this research work, an attempt was made to machine the titanium (Ti6Al4V) alloy utilizing electric discharge machining technique. The distinct process parameters and its impact on the machining performance were identified using the cause-and-effect diagram (CED). The key process parameters identified by CED diagram were current, pulse on time (Ton), aluminium oxide (Al2O3) powder concentration, and gap distance; experiments were conducted by varying the process parameters, experimental runs were designed using the Taguchi mixed orthogonal array. The experimental results revealed that improvement in material removal rate (MRR) was due to the bridging effect; reduction in tool wear rate (TWR) owing to the expansion of spark gap and enhancement in the surface roughness (Ra) was due to the complete flushing of machined debris. The interaction impact was analysed using the contour plot and with the aid of mathematical modelling experimental fits that were identified and the results were validated utilizing the sensitivity analysis. The obtained results were optimized using the technique for order of preference by similarity to ideal solution (TOPSIS) optimization technique.

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Section: Resultsmentioning

confidence: 96%

Improving Sustainability of EDM Sector by Implementing Unconventional Competitive Manufacturing Approach

Anjani²,

Raman

et al. 2022

Advances in Materials Science and Engineering

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“…Mixing of graphene nano powder improves the interelectrode gap distance and discharging frequency. Also, it improves the electrical conductivity of dielectric medium results the electrons transfer from tool to work piece [6][7][8][9]. Addition nano graphene powder causes the transformation of thick streamer into many smaller branches leads to lower surface roughness [10].…”

Section: Introductionmentioning

confidence: 99%

Effect of graphene dispersed coconut biodiesel on the Micro ED milling characteristics of Inconel 718 alloy

Arun Pillai,

Saravana Kumar

2023

Surf. Topogr.: Metrol. Prop.

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Micro Electrical discharge milling is a familiar micromachining process for machining of complex microstructures using a cylindrical tool. In this research work, the influence of process parameters namely capacitance, voltage, threshold on response indicators during machining of Inconel 718 with coconut biodiesel and graphene nano powder dispersed coconut biodiesel is investigated in detail. Further, surface-topography of the machined surface was critically examined using scanning electron microscopy and three-dimensional non-contact roughness tester. Graphene nano powder concentration (0.3g/l) increased the MRR around 68 % compared to coconut biodiesel (BD). A medium order of capacitance (10nF) offered a maximum MRR irrespective of dielectric used. With higher order capacitance, the minimum TWR is obtained due to longer pulse off duration. High surface finish is achieved with graphene nano powder dispersed coconut BD due to uniformly distributed of craters on the machined surface. Recast layer thickness is 3.08 μm, 1.62 μm and 2.34 μm with coconut biodiesel, 0.3 g/L and 0.6 g/L graphene particles mixed coconut biodiesel, respectively. Minimum recast layer is observed with graphene particles mixed coconut biodiesel under considered parametric conditions due to lesser eroded particle deposition. EDS results confirm that the sedimentation of graphene nano powder (increase in carbon %) on work surface results in increase in hardness. Crater size, voids and cracks were reduced with graphene nano powder dispersed coconut BD due to uniform distribution of heat energy over machining region. Results showed that the graphene nano powder mixed coconut biodiesel can be the substitute for mineral oil

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“…Mohanty S. et al [ 30 ] presented the optimization of MRR with the help of the Taguchi method in the EDM of D2 die Steel. Ishfaq K. et al [ 31 ] studied the potential of nano-graphene powder to upsurge the cutting rate and surface quality in the EDM of Ti alloy. Tran T. H. et al [ 32 ] investigated the main process parameters influencing the surface roughness with SiC powder-mixed EDM of hardened steel.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

et al. 2022

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Electric discharge machining with a powder mix dielectric is a promising technique to harden a work piece’s surface using electricity with a high energy density. The quality of the electrical discharge-machined surface is related to its surface integrity in which the surface’s roughness, residual stresses, micro hardness and surface micro cracks are some of the major factors. In this research, graphite powder was mixed in a dielectric with a particle size of 20 µm, 30 µm, and 40 µm, with the concentration of the graphite powder ranging from 2 g/L to 4 g/L. Moreover, the peak current and pulse time on were also coupled with an additive of graphite powder to investigate the effect on the surface quality, i.e., the recast layer thickness, micro hardness and crater depth as well as the material removal rate (MRR) and tool wear rate (TWR). A Box–Behnken design was employed to design the experiments and the experimental results revealed that the graphite powder size and concentration coupled with the electrical parameters (peak current and pulse time on) significantly influenced the recast layer thickness, micro hardness, crater size, MRR and TWR. The crater depth and micro hardness were maximized at a higher concentration and particle size, while the recast layer thickness was reduced with a higher gain size.

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EDM of Ti6Al4V under nano-graphene mixed dielectric: a detailed roughness analysis

Cited by 28 publications

References 33 publications

Improving Sustainability of EDM Sector by Implementing Unconventional Competitive Manufacturing Approach

Improving Sustainability of EDM Sector by Implementing Unconventional Competitive Manufacturing Approach

Effect of graphene dispersed coconut biodiesel on the Micro ED milling characteristics of Inconel 718 alloy

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

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