Effect of Thermo-Physical Properties of the Tool Materials on the Electro-Discharge Machining Performance of Ti-6Al-4V and SS316 Work Piece Materials

Sethy, Sunita; Behera, Rajesh Kumar; Davim, J. Paulo; Rana, Jaydev

doi:10.3390/jmmp6050096

Cited by 8 publications

(3 citation statements)

References 33 publications

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“…Even though it still takes time and money, choosing the right cutting conditions and tools can be done through an experimental campaign [15,16]. Due to these various difficulties of conventional techniques for Ti6Al4V alloy, different non-traditional procedures were employed [17,18]. One such non-traditional process widely preferred for machining difficult-to-cut materials such as Ti6Al4V is the wire electrical discharge machining (WEDM) process.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V

Vora

Shah

Khanna

et al. 2023

JMMP

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Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (Toff), and pulse-on-duration (Toff) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate (MRR) and surface roughness (SR) were selected as output measures for the study. The experiments were carried out by employing Taguchi’s L9 design at three levels. Empirical models were generated, which give the relationship between the input and output factors of the process. To check the acceptability of the model terms, analysis of variance (ANOVA) was used. The regression mode was observed to be significant for the output measures. For MRR, Toff was recorded as the highly significant factor affecting the response values with 74.95% impact, followed by Ton with 16.39%, and current with 6.56%. In the case of SR, Ton was found to be a highly significant factor with a 50.24% impact, followed by current with 43.99%, and Toff with 1.47%. Further, multi-objective optimization by using the HTS technique was performed. The effect of expanded graphite (EG) nano-powder has been studied on the output factors of MRR and SR. The use of EG nano-powder was found to improve WEDM operations as MRR was increased by 45.35%, and simultaneously, SR was reduced by 36.16%. Lastly, the surface morphology of the machined surface was investigated by employing SEM to understand the effect of EG nano-powder. The results have shown a reduction in surface defects by using EG nano-powder compared to the conventional WEDM process.

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Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V

Vora

Shah

Khanna

et al. 2023

JMMP

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“…The authors found that castor oil can be used as the dielectric medium; moreover, the overcut width given by castor oil was lesser than the conventional dielectrics, but the SR achieved in the case of biodegradable dielectric was inferior to the SR magnitude realized with traditional fluids of EDM. Sethy [37] used the three distinct electrodes to determine their machining proficiency in terms of SR, MRR, OC, and EWR during EDM of titanium alloy and stainless-steel materials. Among all the used electrodes, Cu performed outstandingly for both the workpieces and gave the highest MRR, least EWR, intermediate OC, and SR. Gugulothu [38] investigated the cutting ability of deionized water and drinking water in EDM taking titanium alloy as the base material.…”

Section: Introductionmentioning

confidence: 99%

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

Ishfaq

Sana

Rehman

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

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NetZero advancements for the manufacturing industry are aspiring for precision machining of difficult-to-cut materials with a high degree of accuracy, particularly for Ni-based super alloys while meeting climate protocols. The applications and properties of the foregoing materials warrant the usage of the electric discharge machining (EDM) technique. However, given the rising scarcity of resources, there is a compelling need to make this process sustainable. The standard dielectric (kerosene) employed in EDM is hazardous to one's health and fails in terms of long-term productivity. As a result, an effort has been made in this study to evaluate the potential of biodegradable dielectrics, at different copper powder concentrations for sustainable machining of Inconel 600. This investigation evaluated three powder concentrations (0.5, 1.0, and 1.5) g/100 ml for each dielectric. Output responses including electrode wear rate and overcut explicitly aid in ensuring long-term productivity. For example, EWR represents economic assessment, while overcut determines dimensional accuracy. The full factorial design method was used in the experiments, followed by a full statistical examination encompassing, parametric effects and interactions, and signal-to-noise ratio. The findings of this study revealed a decreased EWR (2.69 mm3/min), as well as a minimal overcut (0.33 mm). In case of EWR, about 39% variation in the magnitude has been noted when dielectrics have been varied, whereas approximately 30.9% variation in EWR was observed against the change in the powder concentration. For overcut, the influence of the dielectric on the response magnitude has been further improved as it produces about 61% variation in the OC value. However, the impact of the change in powder concentration for overcut is 8%. It was found that Amla oil with a powder concentration of 0.5 g/100 ml produced the least tool wear, but Sunflower oil at minimum powder concentration (0.5 g/100 ml) produced the minimum overcut. As a result, the combined effect of all of the aforesaid strategies results in more sustainable and dimensionally accurate machining.

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“…Along with the numerous advantages of Ti6Al4V, their higher strength and poor thermal conductivity impose lots of challenges through conventional machining techniques such as excessive tool wear, unsuitable chip breakage, and poor surface finish [6,7]. To overcome these limitations, nonconventional machining techniques can be effectively used for machining hard materials [8][9][10]. Ti6Al4V was used in various advanced manufacturing techniques like 3D printing, including laser powder bed fusion, electron beam melting, directed energy deposition, and nonconventional machining processes [11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Chaudhari,

Khanna,

Patel

et al. 2023

Micromachines

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In the present study, a comprehensive parametric analysis was carried out using the electrical discharge machining of Ti6Al4V, using pulse-on time, current, and pulse-off time as input factors with output measures of surface roughness and material removal rate. The present study also used two different nanopowders, namely alumina and nano-graphene, to analyze their effect on output measures and surface defects. All the experimental runs were performed using Taguchi’s array at three levels. Analysis of variance was employed to study the statistical significance. Empirical relations were generated through Minitab. The regression model term was observed to be significant for both the output responses, which suggested that the generated regressions were adequate. Among the input factors, pulse-off time and current were found to have a vital role in the change in material removal rate, while pulse-on time was observed as a vital input parameter. For surface quality, pulse-on time and pulse-off time were recognized to be influential parameters, while current was observed to be an insignificant factor. Teaching–learning-based optimization was used for the optimization of output responses. The influence of alumina and nano-graphene powder was investigated at optimal process parameters. The machining performance was significantly improved by using both powder-mixed electrical discharge machining as compared to the conventional method. Due to the higher conductivity of nano-graphene powder, it showed a larger improvement as compared to alumina powder. Lastly, scanning electron microscopy was operated to investigate the impact of alumina and graphene powder on surface morphology. The machined surface obtained for the conventional process depicted more surface defects than the powder-mixed process, which is key in aeronautical applications.

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Effect of Thermo-Physical Properties of the Tool Materials on the Electro-Discharge Machining Performance of Ti-6Al-4V and SS316 Work Piece Materials

Cited by 8 publications

References 33 publications

Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V

Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

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