A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

Ishfaq, Kashif; Asad, Mohammed; Anwar, Saqib; Pruncu, Catalin I.; Saleh, Mustafa

doi:10.3390/ma14010023

Cited by 45 publications

(26 citation statements)

References 51 publications

(55 reference statements)

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“…Many pieces of research claimed the amplification of machining performance in terms of output responses like cutting rate, MRR, TWR, and SR when different cutting fluids in the dielectric are exercised. For instance, Kashif et al [ 203 ] comprehensively examined the dispersion of graphene nano-powder mixed in the dielectric medium onto the output parameters (i.e., MRR & TWR) of electric discharge machining (EDM) using three electrodes (copper, brass, and aluminum). They proposed that graphene particles in the dielectric disperse the sparking by raising the plasma channel, which leads to raise the MRR and reduce the TWR.…”

Section: Discussionmentioning

confidence: 99%

Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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Section: Discussionmentioning

confidence: 99%

Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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“…For the selected levels of control variables, a total of 18 experiments were performed with the graphene-based dielectric. Parameter combinations resemble those of Reference [ 48 ] and hence are not reported here for the sake of brevity. The powder of graphene nanoparticles was added in a concentration of 0.5 g/L into the dielectric kerosene.…”

Section: Methodsmentioning

confidence: 99%

“…Moreover, it also causes dissimilar overcut magnitudes in different cutting orientations. This aspect was not assessed in the previous study [ 48 ] and thereof authors extend their work to comprehensively investigate the role/influence of graphene addition on the dimensional accuracy of the machined cavity. It should be mentioned that overcut magnitude is of paramount importance in governing the dimensional accuracy of the cut cavity.…”

Section: Introductionmentioning

confidence: 99%

“…Addition of nano-graphene into dielectric allows an increase of the cutting rate by a great extent. Therefore, authors have already discussed the role of graphene nano-particles during evaluation of material removal rate and tool wear rate by EDM process as long as Ti-6Al-4V is used as workpiece material [ 48 ]. However, based on the previous findings it has also been noted that the inclusion of such additives reduces the control over the spark discharges.…”

Section: Introductionmentioning

confidence: 99%

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EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

Ishfaq

Asad

Harris³

et al. 2022

Nanomaterials

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Ti-6Al-4V is considered a challenging material in terms of accurate machining. Therefore, electric discharge machining (EDM) is commonly engaged, but its low cutting rate depreciates its use. This issue is resolved if graphene nanoparticles are mixed in the dielectric. However, the control over the sparking phenomenon reduces because of the dispersion of graphene particles. Subsequently, the machined profile’s geometric accuracy is compromised. Furthermore, the presence of nanographene induces different sparks along axial and radial cutting orientations. This aspect has not been comprehensively examined yet and dedicatedly targeted in this study to improve the quality of EDM process for Ti-6Al-4V. A total of 18 experiments were conducted under Taguchi’s L18 design considering six parameters namely, electrode type, polarity, flushing time, spark voltage, pulse time ratio, and discharge current. The aluminum electrode proved to be the best choice to reduce the errors in both the cutting orientations. Despite the other parametric settings, negative tool polarity yields lower values of axial (ADE) and radial errors (RDE). The developed optimal settings ensure 4.4- and 6.3-times reduction in RDE and ADE, respectively. In comparison to kerosene, graphene-based dielectric yields 10.2% and 19.4% reduction in RDE and ADE, respectively.

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“…Titanium and its alloys have been widely used in aerospace and biomedical applications due to attractive properties, such as high specific strength, excellent corrosion resistance, and cryogenic properties [1][2][3]. However, as a difficult-to-machine material, titanium and its alloys are difficult to be machined by traditional machining methods, especially when involving a micro-scale feature.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Liu

Chen³

et al. 2021

Materials

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Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

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A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

Cited by 45 publications

References 51 publications

Progressing towards Sustainable Machining of Steels: A Detailed Review

Progressing towards Sustainable Machining of Steels: A Detailed Review

EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

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