Experimental investigation on surface characteristics in Electrical Discharge Surface Grinding (EDSG) of 6061Al/Al<sub>2</sub>O<sub>3p</sub> 10% composite

Choudhary, Rajesh; Kumar, Harish; Singh, Shankar

doi:10.1080/2374068x.2018.1495800

Cited by 4 publications

(4 citation statements)

References 22 publications

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“…Electrical discharge surface grinding and high-speed EDM drilling are examples of hybrid machining processes where one conventional and one spark erosion process is involved. 6,7 A recent approach termed powder mixed wire EDM (PMWEDM) has been introduced in existing research work where conductive or non-conductive powders are 1 Production Engineering Department, Jadavpur University, India 2 Mechanical Engineering Department, NITTTR Kolkata, India combined with the dielectric to create a significant change in performance. 8 The suspended powder is produced a better discharge in the plasma channel.…”

Section: Introductionmentioning

confidence: 99%

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Chakraborty

Mitra

Bose

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

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Section: Introductionmentioning

confidence: 99%

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Chakraborty

Mitra

Bose

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Si powder of 4 g/l concentration provided the best surface quality, whereas 8 g/l Si powder modified the surface structure by generating oxide and carbide layer on the machined surface [24]. Another hybridisation technique of EDM, abrasive powder mixed surface electric discharge machining has been conducted and investigated the influenced parameter on surface properties [25][26][27].…”

Section: Introductionmentioning

confidence: 99%

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

Chakraborty

Mitra

Bose

2020

IJAME

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The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

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“…As for ECM, machining efficiency and surface finishing are two critical problems that need to be resolved [19], while electrochemical discharge machining (ECDM) is an efficient processing method [20]. In the process of ECDM machining of MMCs, it can not only obtain a higher MRR compared to EDM [21], but also the electrochemical effect in the process can promote the detachment of the silicon carbide phase and prevent it from accumulating on the machined surface.…”

Section: Introductionmentioning

confidence: 99%

Electrochemical Discharge Grinding of Metal Matrix Composites Using Shaped Abrasive Tools Formed by Sintered Bronze/diamond

Liu

Huang

et al. 2020

Science and Engineering of Composite Materials

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Electrochemical discharge machining (ECDM) is a well-known process for machining of particulate reinforced metal matrix composites (MMCs). However, ECDM process suffers several drawbacks such as the lower material removal rate (MRR), high risks of tool wear rate (TWR) and relatively poor surface quality, etc. This study proposes a kind of electrochemical discharge grinding machining (ECDGM) method which employs a special shaped tool electrode. During the process, not only the can the hybrid action of electrochemical dissolution, spark erosion, and abrasive grinding improve the performance of machining MMCs, but also the special shaped of the tool electrode can be used to discharge the machined debris. And thus a higher machining efficiency and lower TWR can be obtained. The performance of developed process was conducted on machining of SiC particulate reinforced aluminum workpiece. The role of peak curre+nt, pulse duration, duty cycle, rotary speed and abrasive grit size has been investigated on MMR and TWR using the nonabrasive round electrode, abrasive round electrode, and abrasive shaped electrode respectively. The experimental results showed that using the shaped abrasive electrode for machining MMCs can achieve a higher MRR and lower TWR, as compared to the non-abrasive round electrode, abrasive round electrode. Besides, the orthogonal method was employed to analyze the relative importance of the machining parameters on MRR and TWR, it has been observed that MRR is affected by the processing parameters following the order of rotary speed > peak current > duty cycle > pulse duration, and TWR is following the order of peak current > duty cycle > pulse duration > rotary speed.

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Experimental investigation on surface characteristics in Electrical Discharge Surface Grinding (EDSG) of 6061Al/Al₂O_3p 10% composite

Cited by 4 publications

References 22 publications

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

Electrochemical Discharge Grinding of Metal Matrix Composites Using Shaped Abrasive Tools Formed by Sintered Bronze/diamond

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Experimental investigation on surface characteristics in Electrical Discharge Surface Grinding (EDSG) of 6061Al/Al2O3p 10% composite

Cited by 4 publications

References 22 publications

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

Electrochemical Discharge Grinding of Metal Matrix Composites Using Shaped Abrasive Tools Formed by Sintered Bronze/diamond

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Experimental investigation on surface characteristics in Electrical Discharge Surface Grinding (EDSG) of 6061Al/Al₂O_3p 10% composite