Recast layer removal after electrical discharge machining via Taguchi analysis: A feasibility study

Wang, Che-Chung; Chow, Han Ming; Liu, Yang; Lu, Chunte A.

doi:10.1016/j.jmatprotec.2008.10.012

Cited by 106 publications

(36 citation statements)

References 18 publications

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“…Among non-traditional machining process electric discharge machining (EDM) is considered as relatively good alternative having no material hardness and channel shape restrictions [224,225]. But there are also number of problems linked with EDM and wire-EDM such as low productivity, high tool wear rate, lack of precision due to tool wear, unsuitable for batch production or multi-channels [226], thick recast layer (from 2.5 to 30 µm) [227], heat affected layer of 40-100 um [227], thick white layers (6-8 µm) with micro-cracks [228], poor surface integrity [229] and necessary post processing requirements [230]. Chemical etching is another alternative for the fabrication of micro-channels but it offers troubles of having high aspect-ratio micro-channels [231].…”

Section: Fabrication Techniquesmentioning

confidence: 99%

“…The width, depth, and length of each microgroove were about 150, 300, and 50 mm, respectively, and 16 grooves were produced on each plate. Thick white layers (6-8 µm) with micro-cracks [228] Micro-cracks [257,258] Poor surface integrity [229] Post processing requirements [230] Less fatigue life [259] ECM High material removal rates Good surface integrity [261] Less heat affected zone [262] High tooling cost Suitable for large batch sizes [226] Salt film on machined surface [261] Selective corrosion due to the formation of a porous salt [271] Decrease working time [271] Reductions in vertical and horizontal forces [272] Less stresses in the tools [273] Overlapping grit marks [272] Laser/plasma assisted (cutting, drilling and surface modification) 30 % reduction in cutting force [114] Improved surface roughness 40 % [115,275] Increase in tool life [275,276] No micro-crack during laser surface melting [277] Increase in hardness by laser surface treatment [278] Compressive residual stresses [115] Thicker compressive zone (40-70 µm)…”

Section: Fabrication Techniquesmentioning

confidence: 99%

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Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Darwish

Ahmed

Al‐Ahmari

2016

Advanced Structured Materials

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Laser beam machining (LBM) has proven its applications and advantages over almost all the range of engineering materials. It offers its competences from macro machining to micro and nano-machining of simple-to-complex shapes. The flipside of LBM is the existence of universal problems associated with its thermal ablation mechanism. In order to alleviate or reduce the inherent problems of LBM, a massive research has been done during the past decade and in turn build a relatively new route of laser-hybrid processes. The hybrid approaches in laser ablation have demonstrated much improved results in terms of material removal rate, surface integrity, geometrical tolerances, thermal damage, metallurgical alterations and many more. This chapter reviews the research work carried out so far in the area of LBM and its hybrid processes for different materials and shapes.

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Section: Fabrication Techniquesmentioning

confidence: 99%

Section: Fabrication Techniquesmentioning

confidence: 99%

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Darwish

Ahmed

Al‐Ahmari

2016

Advanced Structured Materials

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“…Damaged surface layer with poor surface integrity, micro cracks, heat affected zone are the major shortcoming in rough cutting operation (Lee & Li, 2003;Wang et al, 2009;Jangra, 2012). The defects are due to high heat energy generated across the electrodes and re-solidification of melted debris's that do not flushed out quickly out of a narrow spark gap (Puri & Bhattacharyya, 2003;Rebelo et al, 1998;Sarkar et al, 2011).…”

Section: Trim Cutting Operationmentioning

confidence: 99%

An experimental investigation and statistical modelling for trim cutting operation in WEDM of Nimonic-90

Kumar¹,

Kumar²,

Jangra³

2015

10.5267/j.ijiec

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Trim cutting operation in wire electrical discharge machining (WEDM) is considered as a probable solution to improve surface characteristics and geometrical accuracy by removing very small amount of work materials from the surface obtained after a rough cutting operation. In this study, an attempt has been made to model the surface roughness and dimensional shift in trim cutting operations in WEDM process through response surface methodology (RSM). Four process parameters; namely pulse-on time (Ton), servo voltage (SV), wire depth (Wd) and Dielectric flow rate (FR) have been considered as input parameters in trim cutting operations for modelling. Desirability function has been employed to optimize multi performance characteristics. Increasing the value of Ton, Wd and FR increases the surface roughness and dimensional shift but increasing SV decreases both surface roughness and dimensional shift. Quadratic models have been proposed for both the performance characteristics. In present experimentation, thickness of recast layer was observed in the range of 6μm to 12μm for low to high value of discharge parameters.

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“…and dielectric conditions (dielectric conductivity, flow rate). Since the material removal takes place because of the high localized heating and the repetitive electrical sparks, top machined surface consists of poor surface integrity having hollow cavities and several micro-cracks (Lee & Li, 2003;Wang et al, 2009). Top machined layer consists of recast layer or white layer which is a re-solidified melted material on work surface, which is not completely flushed during the process.…”

Section: Introductionmentioning

confidence: 99%

An experimental study on trim cutting operation using metal powder mixed dielectric in WEDM of Nimonic-90

Kumar¹,

Jangra²,

Kumar³

2016

10.5267/j.ijiec

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This paper presents an experimental study on rough cut, trim cut using distilled water as a dielectric fluid and Al & Si metal powders in dielectric fluid for WEDM of Nimonic-90. First, the influence of discharge energy (DE) in rough cut is evaluated for machining rate (MR) and surface roughness (SR) and compared with trim cut without any metal powder additives in dielectric fluid. The effect of Al and Si metal powders (varying concentration of 1g/L, 2g/L and 3g/L) in dielectric fluid is studied separately and comparison is also made for MR, SR, recast layer and micro hardness of machined Nimonic-90. From the results it is observed that using trim cut, a fine and uniform surface texture is obtained irrespective of the high discharge energy of rough cut. Al and Si powders additives show a significant reduction in MR for trim cutting operation whereas a remarkable modification is obtained in surface textures after trim cut using metals powder mixed dielectric. SR improves with a concentration of 1g/L and shows a little increase with high concentration of both metals powder. Using metals powder in dielectric fluid, the recast layer becomes smooth and denser and thus, micro hardness increases.

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Recast layer removal after electrical discharge machining via Taguchi analysis: A feasibility study

Cited by 106 publications

References 18 publications

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

An experimental investigation and statistical modelling for trim cutting operation in WEDM of Nimonic-90

An experimental study on trim cutting operation using metal powder mixed dielectric in WEDM of Nimonic-90

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