Optimization of process parameters using graphene-based dielectric in electric discharge machining of AISI D2 steel

Hanif, Muhammad; Wasim, Ahmad; Shah, Abdul Hakim; Noor, Sahar; Sajid, Muhammad; Mujtaba, Nasir

doi:10.1007/s00170-019-03688-0

Cited by 22 publications

(14 citation statements)

References 18 publications

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“…Table 1 shows the results of ANOVA for SR. A 95% confidence level or a significance criterion of 5% (α = 0.05) were used to evaluate the predictions. 5 Table 1 shows that the R-sq (adj) and R-sq data are 92.56% and 95.35%, respectively, confirming the regression model's ability to provide rigorous investigation of the factors for SR. Current intensity (0.004), discharge time (0.023) and HA amount (0.033) are statistically significant for SR, with p values less than 0.05 according to the previous studies. 5,10,17,18,41 A , B , and C each contribute 56.68%, 19.82%, and 15.75%, respectively to SR. To conclude, addition of HAp to the working fluid along with the discharge time and current intensity affected SR.…”

Section: Resultsmentioning

confidence: 62%

“…Consequently, a separate coating procedure is necessary, raising the overall cost of the product. 4,5…”

Section: Introductionmentioning

confidence: 99%

“…Thus, the overheating should be carried away from the operation gap. 4,5,14 To circumvent these restrictions, a new technology known as powder mixed-EDM (PM-EDM) has been suggested in which the powders attributing to high electrical conductivity are added to the working dielectric. Mixing of electrically conductive powders such as Cu, Si, Al, Ag, Ti, TiO 2 , Gr, TiC, SiC, and Al 2 O 3 in the EDM system were reported to improve MER and surface quality with the shallow craters formation due to homogeneous distribution of the created sparks and thermal energy and to reduce SR, TER, and RLT owing to enhancing the flushing system by improving the tools’ gap and rubbing impacts of the eroded debris.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of hydroxyapatite powder mixed electric discharge machining process to improve modified surface features of 316L stainless steel

Danish

Al-Amin

Abdul-Rani

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Traditional methods for producing 316L steel with a desired roughness and a uniform thin coating for sufficient bioactivity and long-term durability are highly difficult and require post-processing. Electric discharge machining (EDM) is a nontraditional process that can accomplish both machining and coating the surface concurrently. This study provides a thorough examination of the impacts of EDM process parameters on the machining responses, which are significantly necessary for processing 316L steel to reach its full potential. The nano-hydroxyapatite particles added EDM method is used to improve the machining and the surface responses. EDM process parametric optimization is conducted using Taguchi's design to achieve the lowest surface roughness of 2.04 µm and a recast layer thickness of 6.11 µm. As a machinability metric, the greatest material erosion rate (MER) of 20.64 mg/min is achieved. Current intensity, discharge period and hydroxyapatite amount are identified to be important predictors for MER, surface roughness and recast layer thickness. Scanning electron microscope with the energy dispersive X-ray spectrums and atomic force microscopic images validate the machined surface morphology, elemental compositions and surface topography. Errors of the confirmatory tests are less than 10%, showing that the projected solution sets by the grey wolf optimizer are highly accurate. The study shows a thin recast layer with both nano and micro-surface roughness formation, which have a great importance in biomedical applications.

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Section: Resultsmentioning

confidence: 62%

“…Consequently, a separate coating procedure is necessary, raising the overall cost of the product. 4,5…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Optimization of hydroxyapatite powder mixed electric discharge machining process to improve modified surface features of 316L stainless steel

Danish

Al-Amin

Abdul-Rani

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Through literature review, it was observed that experiments were designed using different statistical and mathematical models by varying process parameters like pulse on time, pulse off time, peak current, gap voltage, spark gap, polarity or duty factor. [14][15][16][17][18][19][20][21] These process parameters influenced the performance parameter, primarily Material Removal Rate, Tool Wear Rate, Surface Roughness, Overcut and Electrode Wear Rate, to name a few. [22][23][24][25][26] Machining mechanism of EDM and its working EDM is a derivative of spark machining and is characterized by its non-contact machining process.…”

Section: Essential Parameters In Electric Discharge Machiningmentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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“…This was because the increase in current increased the heat transferred to the work surface, resulting in an improved material removal by the removal of debris of a larger size. Hence, it created large-sized craters on the work surface that rose the surface roughness [35].…”

Section: Effect Of Peak Current On the R A Mrr And Twrmentioning

confidence: 99%

Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process

et al. 2021

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Difficulty in debris removal and the transport of fresh dielectric into discharge gap hinders the process performance of electrical discharge machining (EDM) process. Therefore, in this work, an economical low frequency vibration platform was developed to improve the performance of EDM through vibration assistance. The developed vibratory platform functions on an eccentric weight principle and generates a low frequency vibration in the range of 0–100 Hz. The performance of EDM was evaluated in terms of the average surface roughness (Ra), material removal rate (MRR), and tool wear rate (TWR) whilst varying the input machining parameters viz. the pulse-on-time (Ton), peak current (Ip), vibration frequency (VF), and tool rotational speed (TRS). The peak current was found to be the most significant parameter and contributed by 78.16%, 65.86%, and 59.52% to the Ra, MRR, and TWR, respectively. The low frequency work piece vibration contributed to an enhanced surface finish owing to an improved flushing at the discharge gap and debris removal. However, VF range below 100 Hz was not found to be suitable for the satisfactory improvement of the MRR and reduction of the TWR in an electrical discharge drilling operation at selected machining conditions.

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Optimization of process parameters using graphene-based dielectric in electric discharge machining of AISI D2 steel

Cited by 22 publications

References 18 publications

Optimization of hydroxyapatite powder mixed electric discharge machining process to improve modified surface features of 316L stainless steel

Optimization of hydroxyapatite powder mixed electric discharge machining process to improve modified surface features of 316L stainless steel

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process

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