Machinability investigation using Cu-mixed biodegradable dielectric for eco-friendly/sustainable machining of Ni-based superalloy

Ishfaq, Kashif; Rehman, Mudassar

doi:10.1007/s00170-023-10836-0

Cited by 3 publications

(1 citation statement)

References 49 publications

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“…When electrons are sped up in an electric field, they collide with the atoms in the dielectric medium, leading to avalanche impact ionization. This forms a thin plasma channel packed with electrons and positively charged ions released from the anodic side [17,18]. The kinetic energy of the electrons colliding with the anode surface and the ions colliding with the cathode surface is converted into thermal energy.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Density, Surface Tension, and Viscosity of Molten Ni‐Based Superalloys Using the Maximum Bubble Pressure and Oscillating Crucible Methods

Nishi,

Matsumoto,

Yamano

et al. 2024

steel research int.

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Accurate data on the high‐temperature thermophysical properties, which are density, surface tension, and viscosity, are indispensable for performing high‐precision casting simulations of Ni‐based superalloys. Viscosity is the most important thermophysical property for thermofluidic analysis. However, measuring the viscosity of an alloy, which is lower than that of molten glass, is difficult, and experimental viscosity data are limited. Herein, the density of Ni‐based superalloys is measured using the maximum bubble pressure (MBP) method to determine viscosity. The viscosity is evaluated using the oscillating crucible method. The surface tension is simultaneously measured using the MBP method. In these results, the average density values [kg m−3] of Alloy 65, Alloy 718, Alloy WA, and Alloy 720 are 7.52 × 103, 7.43 × 103, 7.82 × 103, and 7.52 × 103, respectively. The average surface tension values [N m−1] of Alloy 65, Alloy 718, Alloy WA, and Alloy 720 are 1.55, 1.54, 1.47, and 1.51, respectively. The fitting equations of the molten Ni‐based superalloys are as follows. 1) Alloy 65: ; 2) Alloy WA: ; 3) Alloy 720: ; 4) Alloy 718: .

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Machining Performance Analysis of Ti6-Al-4V in Powder-Mixed EDM Using Green Dielectric Oil

Pal,

Debnath,

Mahapatra

2024

J. Mol. Eng. Mater.

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In this investigation, the factors were oil type ([Formula: see text]), powder type ([Formula: see text]), and powder concentration ([Formula: see text]) level, and the machining parameters were the voltage (V), capacitance (pf), pulse-on time ([Formula: see text]), and pulse-off time ([Formula: see text]). The output parameters were the material removal rate (MRR), and tool wear rate (TWR). Three types of oils and powders, along with their respective particle concentrations, were selected for this experiment. Neem, Karanja, and sesame oils were mixed with aluminum oxide (Al2O3), chromium (Cr), and nickel (Ni) powder at 4, 6, and 8[Formula: see text]gm/l, respectively, using an overhead stirrer to investigate the conditions under which the green oil powder mixed mixture yielded a higher MRR and lower TWR during the micro-EDM process of titanium alloy (Ti-6Al-4V) using a 0.8[Formula: see text]mm tungsten carbide (WC) tool with fixed machining parameters (240[Formula: see text]V, 100[Formula: see text]pf, 20[Formula: see text][Formula: see text]s [Formula: see text], and 5[Formula: see text][Formula: see text]s [Formula: see text]). All the powders used in this experiment had a 32-micron (450 mesh) size. The Taguchi L[Formula: see text] orthogonal array and grey relational analysis methods were used to design and optimize the input process parameters for both responses. SEM, optical microscopic analysis, and EDS analysis were performed to examine the surface morphology, characteristics of the WC tool, and elemental composition of both the tool and the workpiece material. The optimum conditions for Karanja oil with a Cr powder mixture concentration of 4[Formula: see text]g/l resulted in higher MRR and lower TWR. However, machining with neem and sesame oils resulted in higher TWR and lower MRR.

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Machinability investigation using Cu-mixed biodegradable dielectric for eco-friendly/sustainable machining of Ni-based superalloy

Cited by 3 publications

References 49 publications

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Density, Surface Tension, and Viscosity of Molten Ni‐Based Superalloys Using the Maximum Bubble Pressure and Oscillating Crucible Methods

Machining Performance Analysis of Ti6-Al-4V in Powder-Mixed EDM Using Green Dielectric Oil

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