Influence of near-dry ambiance on WEDM of Monel superalloy

Kumar, Neeraj; Babu, A. Suresh; Sathishkumar, N.; C, Pradeep Kumar

doi:10.1080/10426914.2020.1866191

Cited by 11 publications

(7 citation statements)

References 28 publications

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“…Higher MRR for the wet-WEDM process was due to the fact that dielectric fluid is having higher thermal conductivity as compared to the air-mist mixture [ 51 ]. Lower thermal conductive materials are having less impact on melting and vaporization during the machining process [ 33 ]. This in turn reduces the rate of erosion and thus, MRR.…”

Section: Resultsmentioning

confidence: 99%

“…However, the performance of SR has been substantially improved by 41.56% with the use of the NDWEDM process. This is due to the fact that the lower viscosity of the NDWEDM process reduces the current density [ 33 ]. This in turn results in the formation of tiny shallow craters and produces better surface quality [ 84 ].…”

Section: Resultsmentioning

confidence: 99%

“…Production of higher frequency sparks and thermal energy due to the escalation in the value of Ton has generated larger and deeper craters on the work surface [73,74]. Kumar et al [33] has found a similar trend of increased SR with rise in Ton. The formations of larger craters diminish the surface quality and thus, SR also increased during the NDWEDM process [75].…”

Section: Effect Of Wedm Variables On Responsesmentioning

confidence: 92%

“…However, WEDM operation utilizes dielectric fluid which is a key factor in environmental issues. To overcome this issue, near-dry machining process can be an efficient and effective way by means of providing negligible health hazards [ 33 ]. Near dry machining replaces the EDM oil with a mixture of compressed air and water [ 34 ].…”

Section: Introductionmentioning

confidence: 99%

“…Kumar et al [ 33 ] studied the effect of NDWEDM on nickel-based superalloy-Monel. They utilized a blend of compressed air and deionized water at a suitable proportion for obtaining the near-dry condition.…”

Section: Introductionmentioning

confidence: 99%

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Parametric Optimization and Influence of Near-Dry WEDM Variables on Nitinol Shape Memory Alloy

et al. 2022

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Nitinol-shape memory alloys (SMAs) are widely preferred for applications of automobile, biomedical, aerospace, robotics, and other industrial area. Therefore, precise machining of Nitinol SMA plays a vital role in achieving better surface roughness, higher productivity and geometrical accuracy for the manufacturing of devices. Wire electric discharge machining (WEDM) has proven to be an appropriate technique for machining nitinol shape memory alloy (SMA). The present study investigated the influence of near-dry WEDM technique to reduce the environmental impact from wet WEDM. A parametric optimization was carried out with the consideration of design variables of current, pulse-on-time (Ton), and pulse-off-time (Toff) and their effect were studied on output characteristics of material removal rate (MRR), and surface roughness (SR) for near-dry WEDM of nitinol SMA. ANOVA was carried out for MRR, and SR using statistical analysis to investigate the impact of design variables on response measures. ANOVA results depicted the significance of the developed quadratic model for both MRR and SR. Current, and Ton were found to be major contributors on the response value of MRR, and SR, respectively. A teaching–learning-based optimization (TLBO) algorithm was employed to find the optimal combination of process parameters. Single-response optimization has yielded a maximum MRR of 1.114 mm3/s at Ton of 95 µs, Toff of 9 µs, current of 6 A. Least SR was obtained at Ton of 35 µs, Toff of 27 µs, current of 2 A with a predicted value of 2.81 µm. Near-dry WEDM process yielded an 8.94% reduction in MRR in comparison with wet-WEDM, while the performance of SR has been substantially improved by 41.56%. As per the obtained results from SEM micrographs, low viscosity, reduced thermal energy at IEG, and improved flushing of eroded material for air-mist mixture during NDWEDM has provided better surface morphology over the wet-WEDM process in terms of reduction in surface defects and better surface quality of nitinol SMA. Thus, for obtaining the better surface quality with reduced surface defects, near-dry WEDM process is largely suitable.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%