EDM of titanium foam: electrode wear rate, oversize, and MRR

Mukherjee, Sambaran; Rai, Devesh; Giridharan, Anandi

doi:10.1080/10426914.2021.1981938

Cited by 10 publications

(7 citation statements)

References 24 publications

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“…However, the low thermal conductivity and high toughness of titanium and its alloys make processing them challenging [15,16]. In micro-EDM of titanium, poor thermal conductivity, high hardness and significant chemical affinity result in frequent discharge failures [17,18]. When using different electrode materials and adjusting process parameters, MRR, surface roughness and electrode wear are generally enhanced with increases in current density and pulse duration [19][20][21].…”

Section: Introductionmentioning

confidence: 99%

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Guo,

Luo,

Liang

et al. 2024

Micromachines

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Die-sinking micro-electrical discharge machining (micro-EDM) is a potential method used to fabricate intricate structures without complex electrode motion planning and compensation. However, machining efficiency and poor discharge states are still bottlenecks. This study conducted a comparative investigation into the impact of ultrasonic vibration on die-sinking micro-EDM of polycrystalline diamond (PCD) and pure titanium (TA2). By adjusting discharge parameters, this study systematically evaluated the influence of ultrasonic vibration on these two materials based on discharge waveforms, motion trajectories, effective discharge counts and groove profiles. At an open-circuit voltage of 100 V, ultrasonic vibration promotes die-sinking micro-EDM of PCD. However, when the open-circuit voltage increases to 200 V, ultrasonic vibration exhibits inhibitory effects in general. Conversely, for TA2, ultrasonic vibration shows a promoting effect at both voltages, indicating the differences of ultrasonic vibration-assisted die-sinking micro-EDM on PCD and TA2. For PCD, ultrasonic cavitation improves the discharge gap environment, accelerating the removal of discharge debris. For TA2, due to its poor thermal conductivity, ultrasonic cavitation acts to break the arc, accelerating heat transfer. These research findings provide guidance for ultrasonic vibration-assisted die-sinking micro-EDM in industrial applications.

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Section: Introductionmentioning

confidence: 99%

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Guo,

Luo,

Liang

et al. 2024

Micromachines

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“…Sahu et al [39] gauged the supremacy of EDM when the titanium alloy was studied using EWR, MRR, and SR against the Cu-W-B 4 C electrode. The authors concluded that discharge current was the influencing factor for the MRR, followed by EWR and SR. Mukherjee et al [40] performed the EDM on the metal foams to evaluate the MRR, OC, and EWR in the presence of a brass electrode. The authors found that EWR increased when the discharge current increased and decreased when discharge time and voltage were increased.…”

Section: Introductionmentioning

confidence: 99%

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

Ishfaq

Sana

Rehman

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

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NetZero advancements for the manufacturing industry are aspiring for precision machining of difficult-to-cut materials with a high degree of accuracy, particularly for Ni-based super alloys while meeting climate protocols. The applications and properties of the foregoing materials warrant the usage of the electric discharge machining (EDM) technique. However, given the rising scarcity of resources, there is a compelling need to make this process sustainable. The standard dielectric (kerosene) employed in EDM is hazardous to one's health and fails in terms of long-term productivity. As a result, an effort has been made in this study to evaluate the potential of biodegradable dielectrics, at different copper powder concentrations for sustainable machining of Inconel 600. This investigation evaluated three powder concentrations (0.5, 1.0, and 1.5) g/100 ml for each dielectric. Output responses including electrode wear rate and overcut explicitly aid in ensuring long-term productivity. For example, EWR represents economic assessment, while overcut determines dimensional accuracy. The full factorial design method was used in the experiments, followed by a full statistical examination encompassing, parametric effects and interactions, and signal-to-noise ratio. The findings of this study revealed a decreased EWR (2.69 mm3/min), as well as a minimal overcut (0.33 mm). In case of EWR, about 39% variation in the magnitude has been noted when dielectrics have been varied, whereas approximately 30.9% variation in EWR was observed against the change in the powder concentration. For overcut, the influence of the dielectric on the response magnitude has been further improved as it produces about 61% variation in the OC value. However, the impact of the change in powder concentration for overcut is 8%. It was found that Amla oil with a powder concentration of 0.5 g/100 ml produced the least tool wear, but Sunflower oil at minimum powder concentration (0.5 g/100 ml) produced the minimum overcut. As a result, the combined effect of all of the aforesaid strategies results in more sustainable and dimensionally accurate machining.

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“…MRR increased by 24%, EWR decreased by 23% with the copper electrode, whereas the SR was better with the coated copper electrode. Mukherjee et al [27] experimented with the two forms of tools with current, discharge time, and discharge voltage as processing inputs. They found that the current was the most influential factor in the effect of the wear rate at the inner edge of the hollow tool and front wear for the chamfer tool.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization of PMEDM on Inconel 718 using hybrid T-GRA, TOPSIS, and ANN model

Sai,

Shiek,

Syed

2023

FME Transactions

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Inconel 718 is one of the Nickel-based superalloys considered one of the most difficult-to-machine materials owing to its property to retain hardness at higher temperatures. This study examined the performance of Edcutor-based PMEDM machining on Inconel 718. Taguchi L9 OA has been used with current, Pulse-OFF time & Pulse-ON time as process parameters with a delivery side pressure of 6 bar for the Alumina mixed dielectric. Material removal rate (MRR), Tool wear rate (TWR), & surface roughness (SR) have been taken as output responses. The results have been investigated by MADM techniques, namely Taguchi-based Grey Relational Analysis (T-GRA) & TOPSIS analysis. Furthermore, the ranks obtained from T-GRA & TOPSIS have been validated by developing a single layered ANN model. Ranks predicted by the ANN model are the same for T-GRA and TOPSIS and the R-values are 0.924 & 0.871, respectively. ANOVA has also been used to analyze parameter effects on output responses.

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EDM of titanium foam: electrode wear rate, oversize, and MRR

Cited by 10 publications

References 24 publications

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

Multi-response optimization of PMEDM on Inconel 718 using hybrid T-GRA, TOPSIS, and ANN model

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