Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Kumar, Anish; Kumar, Vinod; Kumar, Jatinder

doi:10.1080/10910344.2016.1165835

Cited by 77 publications

(35 citation statements)

References 33 publications

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“…EDM with kerosene as dielectric fluid produces thinner and porous recast layer as well as finer and harder surface when compared to water emulsion. It was also reported that the white layer thickness decreases with a decrease in pulse duration (electrical energy) [152]. In addition, an EDM automatic finishing setting and the addition of powder to the dielectric fluid reduced the formation of a recast layer [11,153,154] as depicted in Figure 18.…”

Section: Formation and Influence Of Recast Layer On Edmedmentioning

confidence: 88%

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

Aliyu

Rani

Ginta

et al. 2017

Advances in Materials Science and Engineering

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Surface treatment remained a key solution to numerous problems of synthetic hard tissues. The basic methods of implant surface modification include various physical and chemical deposition techniques. However, most of these techniques have several drawbacks such as excessive cost and surface cracks and require very high sintering temperature. Additive mixed-electric discharge machining (AM-EDM) is an emerging technology which simultaneously acts as a machining and surface modification technique. Aside from the mere molds, dies, and tool fabrication, AM-EDM is materializing to finishing of automobiles and aerospace, nuclear, and biomedical components, through the concept of material migrations. The mechanism of material transfer by AM-EDM resembles electrophoretic deposition, whereby the additives in the AM-EDM dielectric fluids are melted and migrate to the machined surface, forming a mirror-like finishing characterized by extremely hard, nanostructured, and nanoporous layers. These layers promote the bone in-growth and strengthen the cell adhesion. Implant shaping and surface treatment through AM-EDM are becoming a key research focus in recent years. This paper reports and summarizes the current advancement of AM-EDM as a potential tool for orthopedic and dental implant fabrication. Towards the end of this paper, the current challenges and future research trends are highlighted.

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Section: Formation and Influence Of Recast Layer On Edmedmentioning

confidence: 88%

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

Aliyu

Rani

Ginta

et al. 2017

Advances in Materials Science and Engineering

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show abstract

“…1b). This can be because of the reason that due to rapid heating and quenching, the local temperature increases more than the melting point of the material resulting in the formation of cracks with the development of high thermal stress exceeding the plastic deformation (Kumar et al, 2016). In this study the size and density of cracks were measured in terms of surface crack density at low and high discharge energy by using equation 1.…”

Section: Surface Structure Of Machined Samplementioning

confidence: 99%

Surface integrity analysis of WEDMed specimen of Inconel 825 superalloy

Kumar¹,

Gupta²,

Kumar³

2018

10.5267/j.ijdns

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WEDM has evolved as a well admired technique for machining of difficult to cut materials such as superalloys. WEDM produces intricate shape and profiles of superalloys by thermoelectric erosion process. But as the process is carried out at very high temperature, the formation of heat affected zone, microcracks, recast layer, porosity etc. resulted in decreased surface integrity of machined specimen and becomes a big problem in WEDM. Discharge energy is the most influencing parameters that affect the surface integrity of WEDmed samples. In this study, Inconel 825, widely used in aerospace industry for making of combustor casing and turbine blades, was machined with WEDM under different discharge energy. The surface topography of the WEDMed specimen was carried cut by using SEM, XRD and EDX techniques. It was observed from the SEM micrograph that the machined surface includes cracks, pockmarks, craters, and pulled out material. The density and sice of craters increase with increase in discharge energy. Surface crack density of 0.0138 μm/μm 2 and recast layer thickness of 34.62μm was obtained for the machined sample at high value of discharge energy while at low value surface crack density of 0.0016 μm/μm 2 and recast layer thickness of 20.99μm was observed. EDX and XRD analysis of the specimen showed that an appreciable amount of elements viz. Fe (Ferrous), Cr (Chromium), Cu (Copper), Ni (Nickel) are migrated to the surface of the workpiece at high value of pulse on time.

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“…Research on deficiency of surface quality in the form of micro-cracks, thermal stress, vast recast layer and improper material removal are existing [12,13]. Improper machining and loss in surface quality may lead to effect on service life of the machined component with residual stress [14][15][16][17]. To identify the influence of process parameters experiments are defined in different combinations of process parameters to predict the responses and also to optimize best process conditions [11,18,19].…”

Section: Introductionmentioning

confidence: 99%

Wire electro spark machining and characterization studies on Ti₅₀Ni₄₉Co₁, Ti₅₀Ni₄₅Co₅ and Ti₅₀Ni₄₀Co₁₀ alloys

Soni

Mashinni

2020

Mater. Res. Express

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The wire electrical discharge machining process (WEDM) is high demand and influenced by various input process parameters namely pulse duration, voltage, wire diameters and wire material. In this research, a smart material made of TiNiCo alloy is investigated to study the machinability using WEDM process. The pulse duration and servo voltage varied to perform the experiments on Ti 50 Ni 49 Co 1 Ti 50 Ni 45 Co 5 and Ti 50 Ni 40 Co 10 smart materials for bone staple applications which were designed by ELCAM software and generated G-code for machining with same software. L-25 orthogonal array used for machining of selected alloys, which is created (L-25 orthogonal array) through Taguchi design of experiment. From the experiments, an analysis was made to study the amount of material removal and average roughness as a response. Further machined areas were subjected to metallurgical characterization techniques such as surface topography, EDS analysis, residual stress calculation and wear mechanism. Tensile residual stress was noticed at higher values of outputs while lower values of residual stress at lower values of outputs which were also confirmed through microstructure and surface topography that smoother surface has been found at lower values of outputs. Moreover, the higher value of residual stress has been noticed on the machined surface of Ti 50 Ni 40 Co 10 alloy while lower on the machined surface of Ti 50 Ni 49 Co 1 alloy. Copper (Cu), Zinc (Zn), Carbon (C) and Oxygen (O) were found as additional elements on the machined surface during the EDS analysis of machined components for each alloy.

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Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Cited by 77 publications

References 33 publications

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

Surface integrity analysis of WEDMed specimen of Inconel 825 superalloy

Wire electro spark machining and characterization studies on Ti₅₀Ni₄₉Co₁, Ti₅₀Ni₄₅Co₅ and Ti₅₀Ni₄₀Co₁₀ alloys

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Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Cited by 77 publications

References 33 publications

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

A Review of Additive Mixed-Electric Discharge Machining: Current Status and Future Perspectives for Surface Modification of Biomedical Implants

Surface integrity analysis of WEDMed specimen of Inconel 825 superalloy

Wire electro spark machining and characterization studies on Ti50Ni49Co1, Ti50Ni45Co5 and Ti50Ni40Co10 alloys

Contact Info

Product

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About

Wire electro spark machining and characterization studies on Ti₅₀Ni₄₉Co₁, Ti₅₀Ni₄₅Co₅ and Ti₅₀Ni₄₀Co₁₀ alloys