Effect of Electrode Coatings in Wire Electrical Discharge Machining of Inconel-718

Dhale, S. R.; Kulkarni, M. L.

doi:10.9790/1684-13040645359

Cited by 9 publications

(2 citation statements)

References 11 publications

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“…The atoms of these two constituents in brass replace each other within the same crystal structure. It delivers a powerful combination of low cost, reasonable conductivity, high tensile strength and improved flush ability (Dhale and Kulkarni 2015). Brass wire electrodes are extensively used on account of their ability to generate stable discharge in spite of their somewhat limited electrical conductivity.…”

Section: Morphology Of Broken Wirementioning

confidence: 99%

Sustainability in wire electrical discharge machining of titanium alloy: Understanding wire rupture

Pramanik

Basak

2018

Journal of Cleaner Production

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To reduce the machining time and energy, it is important to have uninterrupted machining to make the process sustainable. Understanding the factors and mechanism that affect the wire failure is vital to reduce machining time to preserve resources and improve sustainability. Therefore, the mechanism of wire electrode rupture during electrical discharge machining (EDM) of Ti-6Al-4V alloy has been investigated in this study. To aid the analysis, electrolyte flushing pressure (7, 10, 15, 18 MPa), wire tension (800, 1100, 1400 and 1700 gf) and pulse-on-time (4, 6, 8 and 10 μsec) were varied to understand the effects of these parameters on wire rupture.The incidents of wire rupture are high at lower flushing pressure and higher wire tension. The influence of pulse-on-time depends on the interaction ns between wire tension and flushing pressure. The wire rupture occurs at instantaneous high temperature due to generation of unwanted arcs when the EDM debris/wastes are not flushed away properly. Higher wire tension may break the wire even at lower temperature in the machining zone. The wire rupture might be very sudden and/or gradual decrease of cross-section of the wire, however, the tips of the broken wire experience necking before fracture which is contributed to associated wire tension and softening by high temperature. The coating of the wire was disrupted and wear-off around the tips of broken wire. Workpiece material was not detected on the tips, however, trace of oxides islands was detected that formed due to high temperature oxidation of wire materials around the broken tips.

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Section: Morphology Of Broken Wirementioning

confidence: 99%

Sustainability in wire electrical discharge machining of titanium alloy: Understanding wire rupture

Pramanik

Basak

2018

Journal of Cleaner Production

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“…With brass wire, smooth surface is attained, whereas rough surface is produced with zinc coated electrode wire. Dhale and Kulkarni [11] studied the behavior of Inconel-718, with different wire electrodes in WEDM process and measured the performance measures such as MRR and surface finish, conducted experiments by varying Ton, Toff, wire tension, dielectric fluid flushing pressure and wire feed. The investigational output proves that, better MRR and SR was better.…”

Section: Fig 1 Wedm Process [4]mentioning

confidence: 99%

Performance of Zinc Coated Electrode Wire and Parametric Optimization During Profile Cutting of Die-Steel

Saravanan*,

Thiyagarajan,

Somasundaram

2020

IJITEE

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In this work, the effect of brass wire coated with zinc as electrode wire towards maximizing MRR and minimizing SR for the considered input parameters was studied in elaborate during profile cutting of tool steel AISI D3. Experiments were designed based on the L18(21 ,37 ) Taguchi’s orthogonal array considering cutting speed, Ton and Toff, wire tension, servo feed rate and voltage, current and electrode feed rate. The outputs MRR and SR were analyzed and optimized using Grey Relational Analysis (GRA) simultaneously. For both SR and MRR, the drawn chart shows that, the raw data’s lies within upper and lower control limits. The optimum input conditions obtained for higher MRR and lower SR were: 75% of cutting speed, 128 µsec of Ton, 54µsec of Toff, 190A of input current, electrode feed of 3 mm/min with 7 gm of electrode tension, 10V of servo voltage and 2060 mm/min of 10V. Execution of ANOVA on grey grade identifies that, wire tension was the parameter that influences more by 25.89%, followed by Ton and servo voltage by 21.37% and feed rate of wire by 11.89%, with an R2 value of 96.55%. For validating the results, confirmation experiment was also done

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Investigation on the Machining of Inconel-718 Using EDM

Patil¹,

Patil²,

Chaudhari

et al. 2021

Lecture Notes in Mechanical Engineering

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Effect of Electrode Coatings in Wire Electrical Discharge Machining of Inconel-718

Cited by 9 publications

References 11 publications

Sustainability in wire electrical discharge machining of titanium alloy: Understanding wire rupture

Sustainability in wire electrical discharge machining of titanium alloy: Understanding wire rupture

Performance of Zinc Coated Electrode Wire and Parametric Optimization During Profile Cutting of Die-Steel

Investigation on the Machining of Inconel-718 Using EDM

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