Critical analysis of surface integrity parameters and dimensional accuracy in powder-mixed EDM

Sahu, Deepti Ranjan; Mandal, Amitava

doi:10.1080/10426914.2020.1718695

Cited by 66 publications

(23 citation statements)

References 31 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, machined surface of NPMWEDM which was obtained at same machining parameters as that of conventional WEDM process, shows a significant improvement in the surface defects, i.e., significant reduction in micro-pores, globules, and micro-cracks. Significant reduction in the micro-cracks of NPMWEDM process ( Figure 9 ) is due to the uniform sparking between the work material and the tool [ 23 , 41 ]. The reason for large reduction in deposition of debris (globules) and micro-pores of NPMWEDM process is large gap between the tool and workpiece [ 42 , 43 ].…”

Section: Resultsmentioning

confidence: 99%

“…significant reduction in micro-pores, globules, and micro-cracks. Significant reduction in the micro-cracks of NPMWEDM process (Figure 9) is due to the uniform sparking between the work material and the tool [23,41]. The reason for large reduction in deposition of debris (globules) and micro-pores of NPMWEDM process is large gap between the tool and workpiece [42,43].…”

Section: Effect Of Nano-graphene Powder On Response Variablesmentioning

confidence: 99%

“…Important powder characteristics such as size of powder, concentration, thermal and electrical conductivity, and powder density have significant effect in process. Sahu and Mandal [ 23 ] studied the significance of graphite and alumina PMEDM process on surface integrity of nimonic 263 superalloy. Results shows improvement in surface defects for graphite powder mixed EDM process in comparison with other variants.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

et al. 2021

View full text Add to dashboard Cite

In the current scenario of manufacturing competitiveness, it is a requirement that new technologies are implemented in order to overcome the challenges of achieving component accuracy, high quality, acceptable surface finish, an increase in the production rate, and enhanced product life with a reduced environmental impact. Along with these conventional challenges, the machining of newly developed smart materials, such as shape memory alloys, also require inputs of intelligent machining strategies. Wire electrical discharge machining (WEDM) is one of the non-traditional machining methods which is independent of the mechanical properties of the work sample and is best suited for machining nitinol shape memory alloys. Nano powder-mixed dielectric fluid for the WEDM process is one of the ways of improving the process capabilities. In the current study, Taguchi’s L16 orthogonal array was implemented to perform the experiments. Current, pulse-on time, pulse-off time, and nano-graphene powder concentration were selected as input process parameters, with material removal rate (MRR) and surface roughness (SR) as output machining characteristics for investigations. The heat transfer search (HTS) algorithm was implemented for obtaining optimal combinations of input parameters for MRR and SR. Single objective optimization showed a maximum MRR of 1.55 mm3/s, and minimum SR of 2.68 µm. The Pareto curve was generated which gives the optimal non-dominant solutions.

show abstract

Section: Resultsmentioning

confidence: 99%

Section: Effect Of Nano-graphene Powder On Response Variablesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

et al. 2021

View full text Add to dashboard Cite

show abstract

“…While utilizing chromium particles combined dielectric medium, the hardness of the layer was increased by two times during the machining of AISI D2 steel in PMEDM process [24] . The size of the cracks, craters and adhesion particles on the machining surface were signi cantly reduced in PMEDM process while compared with EDM process [25][26][27][28] . It was inferred that usage of different particles with the insulating medium could enhance the surface measures of EDM process [29] .…”

Section: Introductionmentioning

confidence: 97%

Investigation of Surface Quality in Cost of Goods Manufactured (COGM) method of µ-Al2O3 Powder-Mixed-EDM Process on Machining of Ti-6Al-4V

Taherkhania

Ilani

Ebrahimi

et al. 2021

Preprint

View full text Add to dashboard Cite

It is very essential to form such high stregth and hard-to-cut materials by using modern machining methods. It is important to introduce the efforts on modification of the process for improving the machining quality. In the present investigation, an effort was made to analyze the effects of micro size aluminium particles mixed dielectric medium under different powder concentration on machining titanium alloy in electro erosion process. The response-surface-methodology(RSM) based algorithm was utilized to analyze the performance measures by considering machinning time with Cost of Goods Manufactured (COGM) method in PMEDM process. It was found that the micron size powders can significantly help to enhance the surface quality of the Ti-6Al-4V surface during machining in EDM process. The presence of carbon, oxygen elements and the formation of surface oxides and carbides has been found due to the decomposition of dielectric fluid in PMEDM process. The lower deep cavities and uniform machining surface have been produced with the aluminum oxide powder EDM process owing to lower surface cracks density, conductivity. To sum up, investigation and comparison of surface scanning showed that this setting has been implied could be considered by the industries needs more precision.

show abstract

“…Gr was not only reported to improve MRR and tool wear rate [2], but was also found to alloy with machined surface [11]. In a recent study Sahu and Mandal [13] reported Gr based PMEDM to be generating surface with maximum atness for Nimonic 263 in the work that also employed alumina powder in EDM oil. Other than powder material itself, "powder concentration" has also been seen to play its part.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

Saleem

Naqvi

Khan

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Review of the available literature on powder mixed electrical discharge machining (PMEDM) indicates, that most of the research has been done for "die sinking machining mode" whereas the "wire cut machining mode" has not received due attention despite being an important process variant. This work employs Silicon Carbide (SiC) powder mixed dielectric uid for machining of AISI D2 in "wire cut" mode with re-circulating molybdenum wire (an economic and chemically stable proposition as tool). The effect of ve process parameters (powder concentration, peak current, pulse on time, nozzle ushing pressure and stand-off distance) have been evaluated on surface roughness, kerf width, material removal rate and wire wear ratio using Taguchi's approach. It is found that for surface roughness, higher current and low to moderate concentration levels (2 to 4g/l) deteriorate surface quality; higher values of pressure and stand-off distance are also seen to adversely affect it. For material removal rate, pulse on time as well as its interactions with powder concentration and current, are statistically signi cant. A higher pulse on with smaller and moderate powder concentrations (2g/l and 4g/l) reduces MRR. For wire wear ratio, current is the sole signi cant factor (PCR of ~ 65%). SEM analysis of the machined workpiece for the maximum MRR condition quanti es recast layer as ~ 19microns. An indirect comparison with the reported values for non-powdered EDM process indicates that for the similar wire (molybdenum), the use of SiC powder maintains the surface roughness and kerf values, for a much harder D2 material used in this work.

show abstract

Critical analysis of surface integrity parameters and dimensional accuracy in powder-mixed EDM

Cited by 66 publications

References 31 publications

Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

Investigation of Surface Quality in Cost of Goods Manufactured (COGM) method of µ-Al2O3 Powder-Mixed-EDM Process on Machining of Ti-6Al-4V

Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

Contact Info

Product

Resources

About