Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

Laibi, Yousif Q.; Shather, Saad Kariem

doi:10.30684/etj.v38i9a.552

Cited by 4 publications

(5 citation statements)

References 10 publications

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“…This is due to the fact that greater pulse currents induce more intense spark discharge between the electrode and workpiece, which increases the dielectric's flushing away of molten materials and degrades the erosion effect, as documented in a prior study [22]. The TWR was 5.815 gm/min at a pulse on time of 50 μs, as shown in Figure (3). TWR climbed to 7.140 gm/min with an increase of 1.325 in pulse on time, and then fell to 6.785 gm/min with a decrease of 0.355 in pulse on time.…”

Section: Resultsmentioning

confidence: 75%

“…The process involves the utilization of electrical discharges to erode material from a workpiece, making it a proficient approach for severing hard and brittle materials, which present challenges when subjected to traditional machining methods. The utilization of EDM for producing high-precision parts and components has been extensively adopted by various industries, including aerospace, medical, automotive, and electronics [2,3].…”

Section: Introductionmentioning

confidence: 99%

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Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Abdulwahhab,

Ibrahim

2023

ETJ

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The TWR for the pure copper electrode was 0.514 gm/min, while the composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had the lowest TWR at 0.215gm/min.• The pure copper electrode had a higher MRR of 54.5588 mm 3 /min, while the composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had the best MRR at 56.8689 mm 3 /min. • The composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had an improved SR of 3.747 μm versus 3.967 μm for the pure copper electrode. • Current, followed by pulse on/off time, significantly impacted the electrodes' TWR, MRR, and SR.Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50µs followed by a pulse off time of 50 µs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm 3 /min, the composite electrode had the greatest MRR at 56.8689 mm 3 /min. The surface Roughness (SR) of the composite electrode was 3.747μm; this value was lower than that of the pure copper electrode, 3.967μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes.

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Section: Resultsmentioning

confidence: 75%

Section: Introductionmentioning

confidence: 99%

Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Abdulwahhab,

Ibrahim

2023

ETJ

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“…304 stainless steel was used as the blade material to correspond to the experimental model obtained from Laibi and Shather (2020) and Ocaña et al (2015). Table 1 represents the data of the material.…”

Section: Blade Materialsmentioning

confidence: 99%

Prediction of fatigue life of geometrically deviated steam turbine blades under thermo-mechanical conditions

Mashiachidi,

Desai

2024

Front. Manuf. Technol.

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This study explores the intricate factors affecting the fatigue life of steam turbine blades, encompassing steam flow-induced bending, centrifugal loading, vibration response, structural mistuning, and temperature-dependent influences. By focusing on the significance of mistuned steam turbine blades with varying blade geometries due to manufacturing tolerances, this research has paramount relevance for the power generation industries. By employing finite element analysis (FEA) software, a simplified, mistuned, scaled-down steam turbine bladed disk model was developed, considering temperature-dependent material properties. Initial FEA provided insights into the vibration characteristics and steady-state stress responses, with numerical stress distributions evaluated, which were subsequently exported to Fe-Safe software for fatigue life calculations based on centrifugal and harmonic sinusoidal pressure loadings. By investigating the vibration characteristics and response to geometric blade variations, this study affirmed the reliability of the developed FEA model, with findings highlighting the pronounced sensitivity of fatigue life to blade length, width, and thickness variations, in this order. However, in order to validate the developed numerical models, analytical life cycle assessments were calculated, which exhibited a discrepancy of under 3.37%, reinforcing the applicability of the developed numerical methodology to real-world scenarios involving mistuned steam turbine blades experiencing manufacturing deviations in blade geometry.

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“…The developed FE model used ASTM 304 stainless steel. The properties of this steel, obtained from Laibi and Shather [13] and Ocaña et al [14], are presented in Table 1.…”

Section: Numerical Modelling Datamentioning

confidence: 99%

Fatigue life prediction of turbine blades with geometric imperfections made of stainless steel

Mashiachidi,

Desai

2023

tribomat

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This research addresses critical challenges faced by steam turbine blades, particularly in low-pressure (LP) turbines, where premature failures are common due to stress concentrations at the blade root area. The study introduces a numerical methodology aimed at predicting the life of mistuned steam turbine blades, with a focus on variations in blade geometry which have received limited exploration in existing literature. A simplified, scaled-down mistuned steam turbine bladed disc model was developed using Abaqus finite element software. Acquisition of steady-state stress response of the disc models was performed through finite element analysis (FEA). Thereafter, numerical stress distributions were obtained. Subsequently, within Companion software, a Monte Carlo simulation-based probabilistic approach was applied to evaluate and quantify uncertainties in fatigue life for 17 cases. This analysis considered an accepted manufacturing percentage scatter of ± 5 % for the steam turbine bladed disc. That was conducted by selecting mistuning (geometry variation) percentages as the random variables. The methodology demonstrated reliability, correlating well with literature-based and discrete fatigue life results. This study establishes the potential for accurately predicting the fatigue life of mistuned steam turbine blades using the developed methodology.

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Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

Cited by 4 publications

References 10 publications

Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Prediction of fatigue life of geometrically deviated steam turbine blades under thermo-mechanical conditions

Fatigue life prediction of turbine blades with geometric imperfections made of stainless steel

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