Investigation of surface quality in Cost of Goods Manufactured (COGM) method of μ-Al2O3 Powder-Mixed-EDM process on machining of Ti-6Al-4V

Taherkhani, Ali; Ilani, Mohsen Asghari; Ebrahimi, Faramarz; Huu, Phan Nguyen; Long, Banh Tien; Dong, Pham Van; Tam, Nguyen Chi; Minh, Nguyễn Đức; Duc, Nguyen Van

doi:10.1007/s00170-021-07573-7

Cited by 35 publications

(7 citation statements)

References 41 publications

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“…An increased spark gap and decreased dielectric breakdown strength also help improve SR while raising MRR and lowering EWR. In another study conducted by Taherkhani et al [ 33 ], the effect of micro-sized Al 2 O 3 particles was studied to analyze the EDM performance of the Ti6Al4V alloy. Al 2 O 3 powder has been added to the EDM process to obtain an identical machined surface.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Chaudhari

Shah

Khanna³

et al. 2022

Materials

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In the present study, the effect of alumina (Al2O3) nano-powder was investigated for the electrical discharge machining (EDM) of a Nitinol shape memory alloy (SMA). In addition to the nano-powder concentration, other parameters of pulse-on-time (Ton), pulse-off-time (Toff), and current were selected for the performance measures of the material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR) of Nitinol SMA. The significance of the design variables on all the output measures was analyzed through an analysis of variance (ANOVA). The regression model term has significantly impacted the developed model terms for all the selected measures. In the case of individual variables, Al2O3 powder concentration (PC), Toff, and Ton had significantly impacted MRR, TWR, and SR measures, respectively. The influence of EDM variables were studied through main effect plots. The teaching–learning-based optimization (TLBO) technique was implemented to find an optimal parametric setting for attaining the desired levels of all the performance measures. Pursuant to this, the optimal parametric settings of current at 24 A, PC at 4 g/L, Toff at 10 µs, and Ton of 4 µs have shown optimal input parameters of 43.57 mg/min for MRR, 6.478 mg/min for TWR, and 3.73 µm for SR. These results from the TLBO technique were validated by performing the experiments at the optimal parametric settings of the EDM process. By considering the different user and application requirements, 40 Pareto points with unique solutions were generated. Lastly, scanning electron microscopy (SEM) performed the machined surface analysis. The authors consider this to be very beneficial in the nano-powder-mixed EDM process for appropriate manufacturing operations.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Chaudhari

Shah

Khanna³

et al. 2022

Materials

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“…In past studies, several nanopowder concentrations were used by the researchers to enhance the machining outcomes [40]. A comprehensive study shown by Taherkhani et al [41] used microalumina (µ-Al 2 O 3 ) powder to improve the EDM machining performance of Ti6Al4V alloy. The surface defects were largely eliminated due to the presence of alumina powder.…”

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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“…The surface resulting from EDM is characterized by overlapping craters. Their geometric features, including radius, height, depth, curvature, and spacing, determine the surface texture [ 13 , 14 , 15 , 16 , 17 ], which can be controlled by applying appropriate process parameters (voltage, spark current, pulse-on time, etc. ), material and shape of the electrode, and type of dielectric fluid [ 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of EDM Process Parameters on the Surface Finish of Alnico Alloys

Bańkowski

Młynarczyk

2022

Materials

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This article deals with electrical discharge machining (EDM) of an alnico alloy, focusing on how key process parameters affect the surface finish. The experiments were conducted using a BP93L EDM machine. The Box–Behnken design was employed to study the effects of three factors, i.e., spark current, pulse-on time, and pulse-off time, each at three levels, on the surface quality. A specially designed system was employed to increase the effectiveness of the machining process by imparting an additional rotary motion to the tool and an additional rotary motion to the workpiece. The aim was to efficiently remove the eroded metal particles and create a surface with smaller craters. The workpiece surface roughness was measured with a Talysurf CCI lite non-contact profiler. During this precision machining process, the arithmetical mean height (Sa) was less than 1 µm. The surface quality was examined also using scanning electron microscopy (SEM) and optical microscopy (OM). The experimental data were analyzed by means of Statistica to determine and graphically represent the relationships between the input and output parameters.

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Investigation of surface quality in Cost of Goods Manufactured (COGM) method of μ-Al2O3 Powder-Mixed-EDM process on machining of Ti-6Al-4V

Cited by 35 publications

References 41 publications

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

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

Influence of EDM Process Parameters on the Surface Finish of Alnico Alloys

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