A review on parametric optimization of EDM process for nanocomposites machining: experimental and modelling approach

Matanda, Blessing Kudzai; Patel, Vijay; Singh, Bharat; Joshi, Anant; Oza, Ankit D.; Gupta, Manish; Kumar, Sandeep

doi:10.1007/s12008-023-01353-1

Cited by 4 publications

(2 citation statements)

References 98 publications

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“…In the opposite configuration, the polarity is positive [6,7]. The choice of polarity is mainly determined by the higher efficiency of material removal from the workpiece [8][9][10][11][12][13][14]. The phenomenon of material removal in the EDM process is complex, and it relies on the concept of thermoelectric erosion caused by electrical sparks between two conductive materials.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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show abstract

“…Electrical discharge machining (EDM) is a type of nontraditional machining technique that can be effectively used to produce complex shape parts with better surface finish and accuracy [14][15][16]. EDM erodes the workpiece particles by forming regulated electric sparks among the work and tool material in the presence of suitable dielectric fluid [17,18]. The tool and work material need to be electrically conductive for machining through EDM [19,20].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Chaudhari,

Khanna,

Patel

et al. 2023

Micromachines

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In the present study, a comprehensive parametric analysis was carried out using the electrical discharge machining of Ti6Al4V, using pulse-on time, current, and pulse-off time as input factors with output measures of surface roughness and material removal rate. The present study also used two different nanopowders, namely alumina and nano-graphene, to analyze their effect on output measures and surface defects. All the experimental runs were performed using Taguchi’s array at three levels. Analysis of variance was employed to study the statistical significance. Empirical relations were generated through Minitab. The regression model term was observed to be significant for both the output responses, which suggested that the generated regressions were adequate. Among the input factors, pulse-off time and current were found to have a vital role in the change in material removal rate, while pulse-on time was observed as a vital input parameter. For surface quality, pulse-on time and pulse-off time were recognized to be influential parameters, while current was observed to be an insignificant factor. Teaching–learning-based optimization was used for the optimization of output responses. The influence of alumina and nano-graphene powder was investigated at optimal process parameters. The machining performance was significantly improved by using both powder-mixed electrical discharge machining as compared to the conventional method. Due to the higher conductivity of nano-graphene powder, it showed a larger improvement as compared to alumina powder. Lastly, scanning electron microscopy was operated to investigate the impact of alumina and graphene powder on surface morphology. The machined surface obtained for the conventional process depicted more surface defects than the powder-mixed process, which is key in aeronautical applications.

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Multi-objective Optimization of Graphite Powder Mixed Electric Discharge Machining Process Parameters on Inconel 625 Using Genetic Algorithm

Talla,

Muniraju,

Vali

2024

Recent Advances in Mechanical Engineering, Volume 2

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A review on parametric optimization of EDM process for nanocomposites machining: experimental and modelling approach

Cited by 4 publications

References 98 publications

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Multi-objective Optimization of Graphite Powder Mixed Electric Discharge Machining Process Parameters on Inconel 625 Using Genetic Algorithm

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