Surface integrity of tribo-adaptive layer prepared on Ti6Al4V through μEDC process

Mohanty, Shalini; Das, Alok Kumar; Dixit, Amit Rai

doi:10.1016/j.surfcoat.2021.127922

Cited by 15 publications

(6 citation statements)

References 55 publications

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“…At the same time, the kurtosis index (Rku), which describes the sharpness of the profile, takes values around 3 (2.59 < Rku < 4.78), suggesting that the machined surfaces are not compulsorily platykurtic (Rku < 3) or leptokurtic (Rku > 3). Thus, as an overall conclusion can be deduced that the sharpness and the skewness depend on the machining parameters combination and the balance between the material removal (i.e., crater formation) and the material’s insufficient flushing with the simultaneous formation of bulky areas and rims [ 33 ].…”

Section: Resultsmentioning

confidence: 99%

An Optimalization Study on the Surface Texture and Machining Parameters of 60CrMoV18-5 Steel by EDM

et al. 2022

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As a non-conventional machining technology, EDM is used extensively in modern industry, particularly in machining difficult-to-cut materials. CALMAX is a chromium-molybdenum-vanadium tool steel with exceptional toughness, ductility, and wear resistance that has a wide range of applications. Despite the fact that EDM is routinely used in CALMAX machining, the related published research is brief and limited. The current research gives a complete experimental study of CALMAX machining using EDM. A Taguchi Design of Experiment (DOE) was used, using pulse-on current, pulse-on time, and open-circuit voltage as control parameters. Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR) were used to evaluate machining performance, while Ra and Rz were used to estimate Surface Quality (SQ). The produced White Layer (WL) parameters were determined using optical and SEM microscopy, as well as EDX measurements and micro-hardness studies. Finally, for each of the aforementioned indexes, Analysis of Variance (ANOVA) was performed, and multi-objective optimization was based on Grey Relational Analysis (GRA). The results show that higher open-circuit voltage produces lower WL thickness, although by increasing the pulse-on time, the TWR is increased. The average hardness of the WL is increased about 400% compared to the micro-hardness of the bulk material.

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Section: Resultsmentioning

confidence: 99%

An Optimalization Study on the Surface Texture and Machining Parameters of 60CrMoV18-5 Steel by EDM

et al. 2022

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“…On the other hand, as discussed earlier, molybdenum disulphide's lower thermal conductivity (3.5 W mK −1 ), lesser heat energy is transferred to the substrate. With an increase in the concentration of MoS 2 , the size of the crater is comparatively small, so the R a values decrease [28]. Similarly, current also influences the surface roughness parameter.…”

Section: Resultsmentioning

confidence: 99%

“…This results in abrupt deposition on the work surface and micro-cracks formation in the interfacial region, as shown in Figure 6(d). Another reason for the crack formation might be the generation of thermal stresses on the work surface because of sudden quenching within the dielectric fluid [28]. Again, with an increase in duty factor from 40% to 60%, the coating thickness decreases as frequent sparks occur at higher duty factor and simultaneously flushing away the molten material from the work surface.…”

Section: Resultsmentioning

confidence: 99%

Selective surface modification of SS304 using hybrid powder-mixed EDC process

Yadav

Mohanty

Dwivedi

et al. 2022

Surface Engineering

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The present study acclaims the influence of hybrid powders (MoS 2 +W) mixed dielectric fluid on the surface properties of SS304 by the electro-discharge coating (or EDC) process. Hard, wear-resistant, and lubricating surfaces are produced using different blending ratios of the powders infused in the dielectric liquid. The combined effect of both powders on the substrate's surface properties is studied. The process performance is evaluated in terms of wear analysis, surface roughness, coefficient of friction, micro-hardness, and compositional study at different peak current and duty factors. The experimental results show an aggregate increment of micro-hardness from 119.3% to 255.2% compared to substrate. The average surface roughness increases (2.69-4.32 μm) with an increase in tungsten content (from 5% to 50%) in the dielectric and decreases with MoS 2 content. The wear test results reveal a substantial decrease in coefficient of friction (COF = 0.104) with maximum concentration of MoS 2 and 0.274 for maximum tungsten.

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“…This occurrence is associated with the thermophysical behavior of the elements. Aluminum requires almost one-sixth of thermal energy for melting [ 40 ], where vanadium is considered more stable in the same range of melting temperatures [ 41 , 42 ].…”

Section: Resultsmentioning

confidence: 99%

Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining

et al. 2021

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Electrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are widely used in high-end applications owing to their unique intrinsic characteristics. Nonetheless, they have low machinability. The current paper includes an experimental examination of EDM’s Ti-6Al-4V ELI (Extra Low Interstitials through controlled interstitial element levels) process utilizing a graphite electrode. The pulse-on current (IP) and pulse-on time (Ton) were used as control parameters, and machining performance was measured in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The Surface Roughness (SR) was estimated based on the mean roughness (SRa) and maximum peak to valley height (SRz), while, the EDMed surfaces were also examined using optical and SEM microscopy and cross-sections to determine the Average White Layer Thickness (AWLT). Finally, for the indices above, Analysis of Variance (ANOVA) was conducted, whilst semi-empirical correlations for the MRR and TMRR were given using the Response Surface Method (RSM). The results show that the pulse-on time is the most significant parameter of the machining process that may increase the MRR up to 354%. Pulse-on current and pulse-on time are shown to have an impact on the surface integrity of the finished product. Furthermore, statistics, SEM, and EDX images on material removal efficiency and tool wear rate are offered to support the core causes of surface and sub-surface damage. The average microhardness of the White Layer (WL) is 1786 HV.

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Surface integrity of tribo-adaptive layer prepared on Ti6Al4V through μEDC process

Cited by 15 publications

References 55 publications

An Optimalization Study on the Surface Texture and Machining Parameters of 60CrMoV18-5 Steel by EDM

An Optimalization Study on the Surface Texture and Machining Parameters of 60CrMoV18-5 Steel by EDM

Selective surface modification of SS304 using hybrid powder-mixed EDC process

Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining

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