Effect of processing conditions and electrode materials on the surface roughness of EDM-processed hybrid metal matrix composites

Singh, Hardeep; Singh, Jujhar; Kumar, Santosh

doi:10.1016/j.ijlmm.2023.12.001

Cited by 8 publications

(2 citation statements)

References 57 publications

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“…Pressure flushing, jet flushing, and suction flushing are just a few of the different types of flushing methods employed in WEDM. To have higher machining efficiency, choosing the right flushing technique is essential (Singh et al, 2023).…”

Section: Flushing Techniquementioning

confidence: 99%

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Sarala Rubi,

Prakash,

Juliyana

et al. 2024

Front. Mech. Eng.

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A highly advanced thermo-electric machining technique called wire electrical discharge machining (WEDM) can effectively produce parts with varying hardness or complicated designs that have sharp edges and are very difficult to machine using standard machining procedures. This useful technology for the WEDM operation depends on the typical EDM sparking phenomena and makes use of the commonly used non-contact material removal approach. Since its inception, WEDM has developed from a simple approach for creating tools and grown to an outstanding option for creating micro-scale components having the greatest degree of dimensional precision and surface finish characteristics. The WEDM method has endured over time as an efficient and affordable machining alternative that can meet the stringent operating specifications enforced by rapid manufacturing cycles and increasing expense demands. The possibility of wire damage and bent, nevertheless, has severely hindered the process’ maximum potential and decreased the precision as well as effectiveness of the WEDM process. The article examines the wide range of investigations that have been done; from the WEDM through the EDM process’ spin-offs. It describes WEDM investigation that required variables optimization and an assessment of the many influences on machining efficiency and accuracy. Additionally, the research emphasizes adaptive monitoring and control of the process while examining the viability of multiple approaches to control for achieving the ideal machining parameters. Numerous industrial WEDM applications are described with the advancement of hybrid machining techniques. The paper’s conclusion examines these advancements and identifies potential directions for subsequent WEDM research. The investigation on WEDM of metal matrix composites (MMCs) is also reviewed; along with the impacts of various cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on cutting processes outcomes like material removal rate (MRR), kerf width (Kw) and surface roughness (SR). In the present article, future directions for WEDM research were also suggested.

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Section: Flushing Techniquementioning

confidence: 99%

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Sarala Rubi,

Prakash,

Juliyana

et al. 2024

Front. Mech. Eng.

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“…Integration of AI and machine learning into boiler monitoring systems can predict corrosion risks and optimize maintenance schedules for improved efficiency and safety [85][86][87][88][89][90][91][92][93].…”

Section: Intelligent Boiler Monitoring Systemsmentioning

confidence: 99%

Enhancing Resistance to Corrosion, Erosion and Oxidation of Boiler Steels by Surface Modification Techniques

Kumar Pawla,

Kumar,

Kumar

2024

J. Mater. Eng.

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In coal based thermal power plant, the boiler components (superheater, combustion chamber, superheater tubes, boiler walls, reheater etc.) are subjected to harsh environment characterized by high temperatures, aggressive combustion products, and abrasive particles. Corrosion, erosion, and oxidation relentlessly reduce their lifespan and efficiency, posing significant economic and safety concerns. This review explores the potential of surface modification techniques to act as a valiant shield against these destructive forces, extending the life, enhancing the performance, and ensuring the safe operation of boiler components. In this articles various surface modifications techniques including their merits and demerits are discussed with emphasis on thermal spray techniques. From established methods like thermal spraying and laser cladding to innovative approaches like nanocoatings and electrochemical treatments, each technique is meticulously examined for its effectiveness in boosting corrosion resistance, mitigating erosion wear, and minimizing oxidation at crucial boiler locations. This review culminates in a compelling vision of the future, where sophisticated surface modification techniques become an integral part of boiler design and maintenance strategies. By harnessing the power of these technologies, we can usher in an era of more efficient, reliable, and sustainable boiler operation, safeguarding investments and protecting the environment.

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Use of RSM desirability approach to optimize WEDM of mild steel

Pramanik

2024

Phys. Scr.

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Wire Electrical Discharge Machining (WEDM) is a non-traditional material removal process commonly used for precision machining of hard materials such as super alloys, ceramics, carbide, and composite materials. Optimization of process parameters is critical for improving machining efficiency and achieving the desired surface quality. Response Surface Methodology (RSM) systematically optimizes process parameters and investigates their impact on machining performance. WEDM control parameters such as pulse ON Time (TON) (50–60 μs), pulse OFF Time (TOFF) (25–34 μs), gap voltage (VG) (25–250 V), peak current (IP) (1–6 A), and dielectric flow rate (Df) (1–3 LPM) are optimized to reduce surface roughness (SR) and taper angle (TA) while increasing material removal rate (MRR) during the machining of Mild Steel. The optimal parameters are TON as 53 μs, TOFF as 28 μs, IP as 2.65 A, VG as 185 V, and Df as 1.5 LPM. The experimental findings are presented to demonstrate the usefulness of the proposed strategy in optimizing WEDM control parameters. The validation test was conducted under optimal conditions and the results were reported. The manufacturing industries can use RSM optimization in the manufacturing domain.

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Effect of processing conditions and electrode materials on the surface roughness of EDM-processed hybrid metal matrix composites

Cited by 8 publications

References 57 publications

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Enhancing Resistance to Corrosion, Erosion and Oxidation of Boiler Steels by Surface Modification Techniques

Use of RSM desirability approach to optimize WEDM of mild steel

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