Electrolytic-dielectrics: A route to zero recast electrical discharge machining

Ahmed, Shamraze; Speidel, Alistair; Murray, James W.; Ahmed, Nuhaize; Cuttell, Martyn; Clare, Adam T.

doi:10.1016/j.ijmachtools.2022.103941

Cited by 26 publications

(6 citation statements)

References 39 publications

(51 reference statements)

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“…Due to its weak bond with the substrate, the recast layer is prone to delamination, accelerating wear and reducing the workpiece's fatigue life. Hence, it is imperative to remove this deteriorated layer during subsequent processing of precision devices [28]. Prior single-factor experiments have demonstrated that workpieces processed under WEDM parameters T on = 5 μs, T off = 20 μs, SV = 15 V, WT = 120 N, WS = 80 mm/min not only ensure a heightened material removal rate but also afford commendable surface roughness and morphology, even under such conditions.…”

Section: Metallographic Structurementioning

confidence: 99%

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Qian,

Zhao,

et al. 2024

Preprint

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In response to challenges posed by conventional machining methods, an exploratory experimental investigation was conducted to assess the effectiveness of wire electric discharge machining (WEDM) in fabricating turbine disc slots from powder metallurgy superalloy FGH99. The present study conducted a single-factor experiment on WEDM using FGH99 alloys, with the aim of investigating the impact of different WEDM parameters on the material removal rate, surface roughness, and surface morphology. Additionally, the analysis encompassed the characterization of both the heat-affected zone and plastic deformation zone on the workpiece surface. Results show that there is a positive correlation between surface roughness and variables such as pulse width, pulse gap, servo voltage, and wire tension. Conversely, wire speed exhibits an inverse relationship with surface roughness. Notably, the impact of pulse width on surface roughness surpasses that of other parameters. Metallographic examination reveals that under the selected process parameters, while ensuring the efficiency of material removal, superior machining quality was achieved. The absence of conspicuous recast layers on the workpiece surface, with an average thickness of the plastic deformation layer measured at 3.97 µm, indicating favorable processing outcomes. The aforementioned findings provide valuable experimental insights into the WEDM process of FGH99 alloys and offer foundational engineering data for the fabrication of turbine disc slots made from this material.

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Section: Metallographic Structurementioning

confidence: 99%

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Qian,

Zhao,

et al. 2024

Preprint

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“…Compared with deionized water, the number of ions in electrolyte solution is greater, the electrochemical reaction is stronger, and the process performance and processing mechanism of different electrolytes are also different. Shamraze Ahmed et altested the removal effect of different conductivity of sodium chloride, sodium nitrate, sodium sulfate and other solutions on the recast layer of EDM surface [7] . As shown in Figure .4, the thickness of the recast layer on the untreated surface is 6.8μm.…”

Section: Study On Working Fluidmentioning

confidence: 99%

Research of electrical discharge and electrochemical combined machining technology

Qiu,

Dong,

Kong

et al. 2024

Fourth International Conference on Mechanical, Electronics, and Electrical and Automation Control (METMS 2024)

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“…One of the best production methods for incredibly precise processing of electrically conductive materials is EDM. 1,2 The broad range of sectors it can be used in includes tooling, die and molding production, medical equipment, aerospace, automotive, and more. [3][4][5] Notably, EDM is particularly helpful when working with materials whose intricate forms and innate hardness make them difficult to machine.…”

Section: Introductionmentioning

confidence: 99%

Electrical discharge machining process investigation and optimization of parameters for machining of aluminum silicon dioxide (Al7075–SiO₂) composite

Saravanan,

Muthukumaran

2024

Int J Applied Ceramic Tech

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This research paper explores the impact of electrical discharge machining process parameters, including current, pulse‐on time (Ton), and pulse‐off time (Toff), on the material removal rate (MRR) and surface roughness (SR) during the fabrication of aluminum silicon dioxide (Al7075–SiO2) composites. The Al7075–SiO2 composites were produced through stir casting, incorporating 10% by weight of SiO2 reinforcements with an average particle size of 54 µm. To systematically investigate the process parameters' effects, Taguchi's L9 orthogonal array was implemented in the design of experiments. Subsequently, the experimental data underwent analysis of variance (ANOVA) for thorough analysis. The response table for MRR and SR demonstrated that the current significantly influenced both responses (MRR and SR). The ANOVA results provided valuable insights into the percentage contribution of each parameter to the responses. Through the analysis, the optimal control variable settings for achieving the highest MRR were identified as a current of 3 A, a pulse‐on time of 1500 µs, and a pulse‐off time of 1 µs. Conversely, to attain the lowest SR, the ideal control variable settings were determined to be a current of 1 A, a pulse‐on time of 500 µs, and a pulse‐off time of 1 µs. Results also suggest that the error was within admissible range of 5% and the percentage contribution of the current (70.19%) had the largest effect on MRR.

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Electrolytic-dielectrics: A route to zero recast electrical discharge machining

Cited by 26 publications

References 39 publications

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Research of electrical discharge and electrochemical combined machining technology

Electrical discharge machining process investigation and optimization of parameters for machining of aluminum silicon dioxide (Al7075–SiO₂) composite

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Electrolytic-dielectrics: A route to zero recast electrical discharge machining

Cited by 26 publications

References 39 publications

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Research of electrical discharge and electrochemical combined machining technology

Electrical discharge machining process investigation and optimization of parameters for machining of aluminum silicon dioxide (Al7075–SiO2) composite

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Product

Resources

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Electrical discharge machining process investigation and optimization of parameters for machining of aluminum silicon dioxide (Al7075–SiO₂) composite