Reducing micro-machining errors during electric discharge machining of titanium alloy using nonionic liquids

Farooq, Muhammad Umar; Anwar, Saqib; Hurairah, Abu

doi:10.1080/10426914.2023.2236199

Cited by 12 publications

(4 citation statements)

References 34 publications

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“…The non-linear quadratic model was chosen to evaluate parameters’ interactive effects. The linear appears to be significant (p-value 0.005) whereas other squared or two-way parametric interactions are also found to be influential with 90% or 95% confidence 28 , 29 . Therefore, the selection of non-linear quadratic model is merely supported by the fact of comprehensive parametric evaluation.…”

Section: Resultsmentioning

confidence: 93%

Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Kumar,

Yang,

Farooq

et al. 2023

Sci Rep

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This research aims to fabricate an AlSi10Mg parts using Laser Powder Bed Fusion technique with enhanced structural integrity. The prime novelty of this research work is eliminating the balling and sparring effects, keyhole and cavity formation by attaining effective melt pool formation. Modelling of the Laser Powder Bed Fusion process parameters such as Laser power, scanning speed, layer thickness and hatch spacing is carried out through Complex Proportional Assessment technique to optimize the parts' surface attributes and to overcome the defects based on the output responses such as surface roughness on scanning and building side, hardness and porosity. The laser power of 350 W, layer thickness of 30 µm, scan speed of 1133 mm/s, and hatch spacing of 0.1 mm produces significantly desirable results to achieve maximum hardness and minimum surface roughness and holding the porosity of < 1%. The obtained optimal setting from this research improves the structural integrity of the printed AlSi10Mg parts.

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Section: Resultsmentioning

confidence: 93%

Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Kumar,

Yang,

Farooq

et al. 2023

Sci Rep

Self Cite

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“…Conversely, if the P-value is greater than α (P-value > α), it suggests there is no statistical significance among the mean values [29]. Considering the impact of individual parameters (P-value < 0.05), the analysis of variance underscores that the electrolyte concentration and current have the most significant effects.…”

Section: Anova For Grey Relational Analysismentioning

confidence: 99%

Integrating Grey Relation Analysis and Artificial Neural Networks for Optimal Machining of Tungsten Carbide Composite Using Hybrid Electrochemical Discharge

Najm,

Abbas,

Aghdeab

2023

ETJ

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Hybrid Electrochemical Discharge Machining (ECDM) streamlines the manufacturing process for challenging materials. Tungsten carbide (WC) is widely recognized as a formidable material due to its exceptional hardness and its ability to maintain hardness even at elevated temperatures. This study has conducted a comprehensive investigation of the multi-response optimization of ECDM process parameters to enhance the machining of tungsten carbides, utilizing Grey Relation Analysis (GRA) and Artificial Neural Network (ANN) methods. This optimization's primary objective is to achieve the maximum Material Removal Rate (MRR) and machining depth. The study involved a systematically designed experiment based on the Taguchi design method. Scanning Electron Microscopy (SEM) analysis reveals shallow craters, minimal microcracks, and small melt redeposits on the machined surfaces, elucidating the smooth surface achieved after ECD machining. The average surface roughness achieved in this study, utilizing Electrochemical Discharge Machining (ECDM) for tungsten, measured at 0.9275 µm. Optimal parameters were determined, including a current of 80 A, a stand-off distance of 0.1 mm, a 30 mm gap, and an electrolyte composed of KCl + KOH for machining tungsten carbide. The results of the Analysis of Variance (ANOVA) indicate that electrolyte concentration has the most significant impact on machining depth and material removal rate (50.55%), followed by the current value (31.32%). Additionally, the ANN results aligned closely with those obtained through GRA. Compositional analysis of the surface using Energy-Dispersive Xray Spectroscopy (EDS) mapping confirms the presence of oxides and carbon on the machined surface.

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“…The study demonstrated the effectiveness of this method in achieving high-quality microstructures on hard and brittle ceramic materials, offering potential benefits for various engineering and manufacturing applications. Farooq et al [27] conducted a study involving the use of non-ionic liquids and cryogenically treated tool electrodes to investigate micro-machining errors. The study employed an extensive full factorial-based experimental approach, consisting of two sets of experiments: the unmodified process with 12 experiments (using kerosene dielectric as the baseline) and the modified process with 108 experiment.…”

Section: Introductionmentioning

confidence: 99%

Investigation of effect of thickness in micro drilling of Ti-6Al-4V alloy using tungsten copper electrode

Sawant,

Patil

2024

Eng. Res. Express

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The effectiveness and precision of electric discharge machining (EDM) in fabricating holes in challenging materials rely on the careful choice of suitable tools, materials, and process parameters. Nevertheless, the productivity and material removal rate (MRR) of the EDM process impacted by unstable machining conditions and inadequate removal of debris, especially when drilling holes with high aspect ratios. This study focused on examining how various machining conditions influenced the response variables TWR, MRR, and hole taper (HT) were investigated for with different thickness of plates, namely 0.5 mm(W1), 1 mm (W2), and 1.5 mm (W3) of Ti-6Al-4V. The Taguchi based L9 orthogonal array used to design the experiment and the obtained results were subjected to analysis using Analysis of Variance (ANOVA). The effective implementation of appropriate flushing techniques, efficient debris evacuation, and consistent maintenance of machining conditions resulted in enhanced performance for rotary micro EDM (µ-EDM). However, the µ-EDM process is influenced by numerous operating parameters. The findings revealed that the percentage contribution of capacitance and electrode rotation speed (ERS) is more significant compared to voltage. Specifically, for the W3 workpiece, capacitance displayed utmost MRR 0.01894 mm3/min, which is 51.12% and 63.10% greater than the W1 and W2 workpieces respectively. In contrast, the W1 workpiece exhibited the least TWR of 0.000193 mm3/min, which was 50.61% and 67.24% lower than the W2 and W3 workpieces respectively. The W1 workpiece enhanced accuracy as it significantly reduced the HT as compared to the W2 and W3 workpieces. Scanning Electron Microscopy (SEM) was utilized to investigate how workpiece thickness and process parameters influence the surface quality of micro-holes during manufacturing. Through SEM analysis, present study examined the effects of voltage, capacitance, ERS and thickness of the workpiece on the micro-hole surfaces, enabling a deeper understanding of their impact on the final product's quality.

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Reducing micro-machining errors during electric discharge machining of titanium alloy using nonionic liquids

Cited by 12 publications

References 34 publications

Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Integrating Grey Relation Analysis and Artificial Neural Networks for Optimal Machining of Tungsten Carbide Composite Using Hybrid Electrochemical Discharge

Investigation of effect of thickness in micro drilling of Ti-6Al-4V alloy using tungsten copper electrode

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