Enhancing machining rate and geometrical accuracy in electrochemical micromachining of Co-Ni-Cr-W superalloy

Rajkeerthi, E.; Hariharan, P.; Pradeep, N.

doi:10.1080/10426914.2020.1843672

Cited by 20 publications

(10 citation statements)

References 28 publications

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“…An illustrative example of this transition can be found in a study conducted by Rajkeerthi et al in 2021. 22 They explored the electrochemical micromachining of Haynes alloy 188 workpieces, employing an aqueous solution of NaNO 3 as the electrolyte. It was demonstrated that microholes could indeed be produced using a neutral salt solution, albeit requiring a unique pulse design characterized by a distinctive reverse potential drop-off.…”

Section: Methodsmentioning

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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Section: Methodsmentioning

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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“…These generated gas bubbles remove the machined products quickly and stabilize the current flow and improves the machining rate by 2.6 times over normal EMM process. Rajkeerthi et al [8] employed Ø 300 µm fabricated hollow tool in EMM process on nickel based super alloy. The MR and OC improved by 2.04 % and 24.57 % respectively for fabricated hollow tool.…”

Section: Introductionmentioning

confidence: 99%

Enhancing MRR and accuracy with magnetized graphite tool in electrochemical micromachining of copper

Palaniswamy¹,

Seeniappan²,

Thanigaivelan

et al. 2023

CI&CEQ

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Micro hole is the fundamental feature found in any device/components. Hence this paper aims to produces the micro holes using electrochemical micromachining (EMM). The existing machining techniques in EMM for creating micro holes are associated with more overcut (OC). Hence, it is very essential to reduce OC and enhance the machining rate (MR). This paper aspires to investigate the effect of graphite electrode with magnetic force on copper plate. Four different tools namely electromagnetic graphite tool (EMGT), permanent magnet graphite tool (PMGT), graphite tool and stainless steel (SS) tool are employed for these experiments. The major influencing factors are machining voltage in volts, duty cycle in % and electrolyte concentration in g/l was considered on MR and OC. The results exposed that EMGT, PMGT and graphite electrodes produce MR of 106.4%, 74.6 % and 44.5 % over SS tool at parameter level of 23 g/l, 15 V, and 85% respectively. Graphite and EMGT electrode resulting in 11.9% and 3.41 % reduced OC respectively than SS tool at parameter level of 8V, 95% and 28 g/l. Additionally, scanning electron microscope (SEM) picture examination is conducted to identify the magnetic field effect on the work surface.

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“…Researchers addressed this by coating with Polymethyl methacrylate (PMMA) [11,12] to improve osteoconduction and by replacing the alloying element V with Nb and Fe that improves corrosion resistance when compared to Ti6Al4V [13]. There are several works of literature available on surface modifications on the implant materials via Vaccum depositionbased processes such as physical vapour deposition (PVD) and Chemical vapour deposition (CVD) [4,14,15] and other mechanical processes such as shot blasting, laser peening which induces thermal shock and high residual stress [16]. With the surge in the development of non-traditional machining, an upsurge is ascertained in the area of machining efficiency and quality of the product, which finds its efficacy in the areas of medical, optical and precision instruments [14].…”

Section: Introductionmentioning

confidence: 99%

Surface modification of Ti6Al7Nb employing pure waterjet and abrasive waterjet polishing for implant application: comparison study

Pradeep¹,

Sastry²,

Brandão³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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Natural bones in vertebrates are replaced with implants when it fails under fatigue/impact loading conditions. The implants surface roughness is a vital parameter that enhances the osseointegration rate owing to mechanical stability by firm anchoring between the implant and the bone tissue. In this research article, surface modification of Ti6Al4Nb by the action of impingement erosion was executed under two conditions (i) Waterjet polishing (WP) without abrasives; (ii) Abrasive waterjet polishing (AWP) with biocompatible abrasives and studied in correlation to MRR and average surface roughness. The bio abrasives were made in a laboratory that endorses the bone healing characteristics availing 85% hydroxyapatite (HAp) and 15% yttrium stabilized zirconia. SEM, EDS, XRD, AFM and Non-contact surface roughness measurements were used to study the surface morphology of the bio-abrasives and the AWP surface. Experimentally the WP resulted in 73% more material removal rate and with higher average surface roughness Ra by 50% when compared to the AWP. The biocompatibility of Ti6Al4Nb post AWP was found to be favourable with more live cells after performing the MG63 Cell assay for the optimal exp run #11 obtained via the desirability function algorithm.

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Enhancing machining rate and geometrical accuracy in electrochemical micromachining of Co-Ni-Cr-W superalloy

Cited by 20 publications

References 28 publications

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

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

Enhancing MRR and accuracy with magnetized graphite tool in electrochemical micromachining of copper

Surface modification of Ti6Al7Nb employing pure waterjet and abrasive waterjet polishing for implant application: comparison study

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