Characterization of electric discharge machining of titanium alloy utilizing MEIOT technique for orthopedic implants

S, Manoj Prabhakar B; Ranjith, R.; Venkatesan, Sudharshan

doi:10.1088/2053-1591/ac1a2d

Cited by 14 publications

(11 citation statements)

References 54 publications

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“…Normalization was accomplished by the following steps. e difference between the i th element of the X row to the upper and lower circuit of the ideal matrix was calculated as the matrix of (Y ij ) (36 × 2) as shown in equation ( 5) [56]. For beneficiary attributes, matrix Z ij was the maximum of Y 11 and Y 12 , whereas for nonbeneficiary minimum value was taken as portrayed in equations (6) and 7 [57].…”

Section: Relative Index Methodmentioning

confidence: 99%

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Prakash¹,

Ranjith²,

Mohan

et al. 2022

Advances in Materials Science and Engineering

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In this work, an attempt was made to machine the AZ91/5B4C/5Gr hybrid composites in a castor oil electric discharge medium with an objective of attaining green environment. The hybrid composites were produced using stir casting technique in a protective environment. Experiments were conducted by varying dielectric fluid (castor oil and hydrocarbon oil), tool materials (copper, graphite, and brass), polarity, current, pulse-on time, and gap distance in Al2O3 mixed dielectric medium. L36 Taguchi approach was adopted for the design of experiments, and machining performance was accessed in terms of material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra). Because of castor oil’s high thermal conductivity, high kinematic viscosity, and lower dielectric strength, the specimen exhibits 5% higher MRR than EDM oil. When the electrodes were connected to the negative polarity, the Ra was 1.72 μm and 3.66 μm at positive polarity; however, at negative polarity, the TWR was higher than the MRR. The high density and specific heat of castor oil facilitate flushing and uniform heat distribution; as a result, the composite had a Ra of 2.52 μm compared to 2.86 μm when machined with conventional EDM oil. Surface topography showed the specimen machined with hydrocarbon dielectric medium proffers black spots, which were eliminated in castor dielectric medium. Best parametric combination was selected by the Relative Index Method optimization technique.

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Section: Relative Index Methodmentioning

confidence: 99%

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Prakash¹,

Ranjith²,

Mohan

et al. 2022

Advances in Materials Science and Engineering

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“…Higher current values result in increased material removal rates, but they can also lead to excessive tool wear and rougher surface finishes [7,8]. The voltage generates higher spark energy; however, excessive voltage levels can cause instability in the spark gap [9]. Longer pulse on-times generate more heat and Pulse off-time is crucial to prevent overheating and maintain process stability [10].…”

Section: Introductionmentioning

confidence: 99%

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

KT,

et al. 2024

Mater. Res. Express

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In this research, an attempt was made to reinforce aluminium with graphite particles and use it as a tool material with the objective of combining the properties of aluminium and graphite. The micrograph confirms that the graphite particles were uniformly distributed over the aluminium matrix, density reduces and thermal conductivity increases with the addition of graphite particles. Material Removal Rate (MRR) peaks at 12A current before declining due to plasma channel expansion, an optimal Ton of 8µs ws observed, with 4µs Toff yielding higher MRR. Copper electrodes excel due to thermal conductivity, while 5% graphite in aluminum boosts MRR to 31.89mm³/min, additional graphite decreases MRR. TWR rises with shorter Toff until 6µs, then decreases. Gap control impacts TWR, with lower spark gaps causing higher TWR due to intense material removal, and higher gaps leading to increased TWR due to incomplete flushing. Copper electrodes have the lowest TWR due to their high melting temperature. The addition of graphite in aluminum reduces TWR at low currents but is less effective at higher currents. Surface roughness (Ra) decreases with higher current, reaching a minimum of 7.02µm at 12A. Optimal Ton is 8µs (7.56µm), while shorter Toff at 4µs and a 3mm gap yield the best Ra of 7.36µm with A4 composite tool. Copper electrodes result in higher Ra at higher currents, while graphite in aluminum improves surface quality, especially at 5% content. Arcing, an undesirable electrical discharge phenomenon in EDM, adversely affects machining. Experiments revealed a strong correlation between high duty cycles, duty ratios, and arcing propensity, with composite tools being more susceptible due to their variable conductivity. In contrast, non-composite tools, exemplified by copper, withstand higher duty ratios without arcing.

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“…Machining composites was a difficult process because the reinforcing particles in the matrix cause excessive tool wear, resulting in poor surface roughness [20]. Composite materials are preferred to machined using unconventional machining techniques (UCM), as there is no direct contact between the workpiece and the tool occurs, of various UCM process Electric Discharge Machining (EDM) produces components of high precision and accuracy [21].…”

Section: Introductionmentioning

confidence: 99%

Tribological and machining characteristics of AA7075 hybrid composites and optimizing utilizing modified PROMETHEE approach

Ajin

Moses

Dharshini

2023

Mater. Res. Express

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In this research work an attempt was made to reinforce AA7075 composites with B4C and SiC particles through stir casting route. SEM with EDS mapping revealed that the reinforcement were uniformly over the composites and hardness reduces with the addition of SiC particles owing to the inverse hall petch effect. The results revealed that wear rate reduces with addition of SiC particles owing to the formation of mechanically mixed layer and protective oxide layer confirmed through SEM with EDAX mapping. Three distinct cracks were formed, when slides at different temperature as confirmed through worn surface morphology, pits cracks and plasticization of material were the other features observed. The used motor oil properties were analyzed and results divulged that the oil suitable for dielectric fluid. Increase in Material Removal Rate (MRR), reduction in Tool Wear Ratio (TWR) and Surface Roughness (Ra) was observed with the incorporation of powder particles owing to the bridging effect. Black spots, craters, micro pits, globules and micro crack are the distinct observed on the machined surface topography. The modified Preference Ranking Organization METHod for Enrichment of Evaluations (PROMETHEE) optimization technique was utilized to find the optimal parametric combination.

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Characterization of electric discharge machining of titanium alloy utilizing MEIOT technique for orthopedic implants

Cited by 14 publications

References 54 publications

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

Tribological and machining characteristics of AA7075 hybrid composites and optimizing utilizing modified PROMETHEE approach

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