Machining of Inconel 718 with a defined geometry tool or by electrical discharge machining

Baldin, Vitor; Baldin, Claudia Regina Bernardi; Machado, Álisson Rocha; Amorim, Fred L.

doi:10.1007/s40430-020-02358-7

Cited by 19 publications

(2 citation statements)

References 86 publications

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“…However, the limitations of the WEDM process are the machining time compared to other processes and the surface finish of the final product [17,18]. Many studies have been conducted to optimize the process parameters of WEDM in terms of material removal rate (MRR), roughness, eroded residuals, etc.…”

Section: Introductionmentioning

confidence: 99%

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

Gokcekaya,

Günen,

Ceritbinmez

et al. 2024

Int J Adv Manuf Technol

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Inconel 718 alloy is difficult to machine using conventional methods due to its physical properties. Thereby, additive manufacturing (AM) of IN718 components with near-net shapes has been extensively studied. Even though AM processes provide shape and size accuracy, there is still the need for the machining of the AM-processed components to achieve the final shape of a component. Laser powder bed fusion (LPBF) has been successfully utilized to fabricate near-net shape IN718 components; moreover, the microstructure of LPBF-IN718 was unique owing to the AM processing, resulting in differences in grain size, grain boundary characteristics, and grain orientations. Furthermore, these microstructural characteristics are expected to alter the machining performance of IN718. Therefore, this study investigated the wire electro-discharge machining (WEDM) performance of LPBF-718 samples compared to wrought IN718 while focusing on the unique microstructure characteristics of LPBF-IN718 samples (lamella, single-crystal, ploy-crystal). Three different cutting strategies (rough, semi-finish, and finish) were implemented to understand the performance of the multi-pass cutting phenomenon and its effect on the surface of IN718. For all samples, rough (single pass) cutting displayed high roughness, while finish (three passes) cutting exhibited good surface quality. Compositional analyses on the machined surface showed debris formation including Zn and Cu-containing recast material, indicating wire erosion. The surface of single-crystal LPBF-IN718 after the WEDM process was smooth owing to its large grain size and less amount of grain boundary, resulting in slow cutting speed but a good surface finish. Thus, this study, for the first time, investigated the effect of unique microstructural characteristics of LPBF-fabricated IN718 on WEDM performance and machined surface quality.

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Section: Introductionmentioning

confidence: 99%

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

Gokcekaya,

Günen,

Ceritbinmez

et al. 2024

Int J Adv Manuf Technol

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“…Electrical discharge machining (EDM) is a precision machining process in which repetitive controlled sparks are used to remove material from the conductive workpiece materials [ 1 ]. Sparks are produced between the tool (electrode) and the workpiece, which is completely submerged under an insulated working medium referred to as dielectrics [ 2 , 3 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode

Equbal

Khan

et al. 2021

Polymers

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In the present study, cylindrical ABS P400 polymer parts (diameter 6.5 mm) to be used as die-sinking EDM (electric discharge machining) novel electrodes were fabricated using a fused deposition modeling (FDM) process. To meet the conductivity requirement in EDM, ABS parts were metallized using an innovative method that comprised putting aluminum–charcoal (Al–C) on them followed by their copper electroplating. Real-time EDM of the mild steel workpiece was performed using novel electrodes, and machining performance of the electrodes, measured in terms of dimensional accuracy, i.e., change in diameter (ΔD) and change in depth (ΔH) of the cavity, under varying levels of three EDM factors, i.e., current (I), pulse on time (Ton), and pulse off time (Toff), was investigated. Machining results were analyzed using analysis of variance (ANOVA), perturbation graphs, and 3D surface plots. The optimal setting of the EDM parameters for minimizing ΔD and ΔH was determined using the desirability function approach. The suitability of the novel electrodes for EDM was ascertained by comparing their machining results with those of solid copper (SC) electrodes and electrodes fabricated by FDM and metallized using the electro-deposition method (FDM-EM), already reported in the literature, under similar machining conditions. From the results, it was found that ΔD and ΔH were less when EDM was performed using novel electrodes.

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Tool Life and Surface Roughness of Inconel 718 During End Milling Under Dry, Chilled Air and Chilled MQL

Husshini

Kasim

Mohamad

2022

Lecture Notes in Mechanical Engineering

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Machining of Inconel 718 with a defined geometry tool or by electrical discharge machining

Cited by 19 publications

References 86 publications

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode

Tool Life and Surface Roughness of Inconel 718 During End Milling Under Dry, Chilled Air and Chilled MQL

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