A contribution to numerical prediction of surface damage and residual stresses on die-sinking EDM of Ti6Al4V

Rajhi, Wajdi; Alatawi, Ibrahim; Subhani, Tayyab; Ayadi, Badreddine; Alghamdi, Abdulaziz S.; Khaliq, Abdul

doi:10.1016/j.jmapro.2021.06.056

Cited by 25 publications

(9 citation statements)

References 50 publications

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“…The stress is mainly due to the phase transition stress during the transformation of the molten metal into solid metal. The result is close to the literature [17,18].…”

Section: Analysis Of the Residual Stresssupporting

confidence: 90%

Study on Solidification Process and Residual Stress of SiCp/Al Composites in EDM

Zhang

Chang

2022

Micromachines

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To study the change of residual stress during heating and solidification of SiCp/Al composites, a one-way FSI (Fluid Structure Interaction) model for the solidification process of the molten material is presented. The model used process parameters to obtain the temperature distribution, liquid and solid-state material transformation, and residual stress. The crack initiated by the thermal stress in the recast layer was investigated, and a mathematical model of crack tip stress was proposed. The results showed a wide range of residual stresses from 44 MPa to 404 MPa. The model is validated using experimental data with three points on the surface layer.

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“…The stress is mainly due to the phase transition stress during the transformation of the molten metal into solid metal. The result is close to the literature [17,18].…”

Section: Analysis Of the Residual Stresssupporting

confidence: 90%

Study on Solidification Process and Residual Stress of SiCp/Al Composites in EDM

Zhang

Chang

2022

Micromachines

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“…Since Inconel has a higher toughness, the study found that it has a lower crack density. In this direction of surface integrity, few studies were reported [ 124 , 125 , 126 , 127 , 128 ].…”

Section: Performance Measuresmentioning

confidence: 99%

Reviewing Performance Measures of the Die-Sinking Electrical Discharge Machining Process: Challenges and Future Scopes

et al. 2022

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The most well-known and widely used non-traditional manufacturing method is electrical discharge machining (EDM). It is well-known for its ability to cut rigid materials and high-temperature alloys that are difficult to machine with traditional methods. The significant challenges encountered in EDM are high tool wear rate, low material removal rate, and high surface roughness caused by the continuous electric spark generated between the tool and the workpiece. Researchers have reported using a variety of approaches to overcome this challenge, such as combining the die-sinking EDM process with cryogenic treatment, cryogenic cooling, powder-mixed processing, ultrasonic assistance, and other methods. This paper examines the results of these association techniques on various performance measures, such as material removal rate (MRR), tool wear rate (TWR), surface roughness, surface integrity, and recast layer formed during machining, and identifies potential gap areas and proposes a solution. The manuscript is useful for improving performance and introducing new resolutions to the field of EDM machining.

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“…Furthermore, with the augment of peak current, the formation of voids, pockmarks, and crater size increases. As well, at a lower peak current value, there is a high chance of the formation of crack density [23,24]. In addition, it was found that the crack and surface damage of the machined microhole was reduced by decreasing the duration of the current pulses [25].…”

Section: Introductionmentioning

confidence: 99%

Surface morphology and drilled hole accuracy of conductive ceramic composites Si 3 N 4 -TiN and MoSi 2 -SiC on EDMed surfaces

Selvarajan¹,

Venkataramanan²

2022

Preprint

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By using electro-discharge machining (EDM), conductive ceramic composites made of Silicon Nitride and Titanium Nitride (Si3N4-TiN) and intermetallic ceramic composite (MoSi2-SiC) were machined while performance metrics of crucial importance to the EDM process were measured. The two conductive ceramic composites are thoroughly examined using machining parameters including current, spark on time, spark off time, and dielectric pressure. For multiple responses of geometrical errors, such as circularity, cylindricity, and perpendicularity, as well as performance metrics like metal removal rate (MRR), electrode wear rate (EWR), wear ratio, and surface integrity on the machined surface of the workpiece and electrode. Taguchi’s based L9 Orthogonal array (OA) based onthe design of experiments(DOE) is used to carry out the experimental runs to identify the optimum parameters of Si3N4–TiN and MoSi2–SiC ceramic composite. By analyzing the performance of conductive ceramic composites, the optimized results achieved from these approaches are suggested to improve themetal removal rate and lower the tool wear ratio, surface roughness and geometrical tolerances. An elaborated investigation of material removal mechanism and the surface topographyas examined by the SEM instrument with EDAX report in the machined surface for both composites. By analysing the machined surface on the best hole with the best electrode and the worst hole with the worst electrode the surface textures from nine holes and electrodes for ceramic composites are studied. Thus, simultaneously analysed and established EDM process appears to be a promising method for producing excellent surfacesin anelectrically conductive Si3N4–TiN and MoSi2–SiC composite under slow process parameters condition of conductive ceramic composites.

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A contribution to numerical prediction of surface damage and residual stresses on die-sinking EDM of Ti6Al4V

Cited by 25 publications

References 50 publications

Study on Solidification Process and Residual Stress of SiCp/Al Composites in EDM

Study on Solidification Process and Residual Stress of SiCp/Al Composites in EDM

Reviewing Performance Measures of the Die-Sinking Electrical Discharge Machining Process: Challenges and Future Scopes

Surface morphology and drilled hole accuracy of conductive ceramic composites Si 3 N 4 -TiN and MoSi 2 -SiC on EDMed surfaces

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