Effects of dielectric fluids on surface integrity for the recast layer in high speed EDM drilling of nickel alloy

Li, Chaojiang; Xu, Xi; Li, Yong; Tong, Hao; Ding, Sheng; Kong, Quancun; Zhao, Lei; Ding, Jun

doi:10.1016/j.jallcom.2018.12.283

Cited by 75 publications

(29 citation statements)

References 31 publications

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“…The transformation of electrical energy into thermal energy leads to the vaporization and melting of the material of the workpiece and of the tool electrode [13][14][15]. Due to the presence of high temperature (about 10,000 • K) in the machining zone, the quality of the machined surface is unsatisfactory because of the occurrence of erosion micro-craters, re-solidified material, heat affected zone and white layer (recast layer) involving micro-cracks and residual tensile stresses [16][17][18]. A disadvantage of the process is also a low material removal rate and high tool wear reaching above 50% [19].…”

Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

“…However, efficient flushing often requires additional fixtures or adjustment of the machine. It is worth underlining that the properties of the working fluid such as electric conductivity and viscosity can substantially affect the working fluid flow, machining efficiency, electrode wear and recast layer thickness [18,37].…”

Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

“…After the EDM with the use of deionized water, micro-parts with a surface roughness parameter of Ra = 22 nm [16] and Ra = 12-43 nm were obtained [43]. Additionally, an analysis of the results of the EDM with the use of deionized water in the Inconel 718 alloy shows that the recast layer thickness can be reduced to the average thickness of 3-8 µm [18]. Overall, for machining efficiency and machined surface quality, deionized water is a better dielectric for electrical discharge machining of nickel-based superalloys.…”

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

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Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

et al. 2020

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Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of the most effective methods of making high-aspect-ratio holes is electrical discharge drilling (EDD). While drilling high aspect ratio holes, a crucial issue is the flushing of the gap area and the evacuation of the erosion products. The use of deionized water as the dielectric fluid in the EDD offers a considerable potential. This paper includes an analysis of the influence of the machining parameters (pulse time, current amplitude and discharge voltage) on the process performance (drilling speed, linear tool wear, taper angle, hole’s aspect ratio, side gap thickness), during the EDD with the use of deionized water in the Inconel 718 alloy. The obtained through holes were subjected to the extended analysis. The impact of the initial working fluid temperature and pressure on the conditions of the flow through the electrode channel was also subjected to the analysis. The deionized water properties were changed by applying an initial temperature. Based on the results of an analysis of the previous research, the EDD of the through holes was performed for a pre-set initial temperature (~313.15 °K) and initial pressure of the working fluid (8 MPa) and selected process parameters. An analysis of the results indicates increasing of hole’s aspect ratio by about 15% (above 30), decreasing the side gap thickness by about 40% and enhanced surface integrity.

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Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

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Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

et al. 2020

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“…The machining program will be updated after each operation to decrease the idle time. The influences of various fluids on the formation of the white layer were analyzed by Li et al [26]. The author concluded that a higher conductivity of the fluid resulted in a thicker white layer and an increased cooling speed caused a thin affected layer.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Electrical Discharge Drilling Process of SS304 for Energy Efficiency, Product Quality, and Productivity

2020

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The electrical discharge drilling (EDD) process is an effective machining approach to produce various holes in difficult-to-cut materials. However, the energy efficiency of the EDD operation has not thoroughly been considered in published works. The aim of the current work is to optimize varied parameters for enhancing the material removal rate (MRR), saving drilled energy (ED), and decreasing the expansion of the hole (HE) for the EDD process. Three advanced factors, including the gap voltage adjustor (GAP), capacitance parallel connection (CAP), and servo sensitivity selection (SV), are considered. The predictive models of the performances were proposed with the support of the adaptive neuro-based fuzzy inference system (ANFIS). An integrative approach combining the analytic hierarchy process (AHP) and the neighborhood cultivation genetic algorithm (NCGA) was employed to select optimal factors. The findings revealed the optimal values of the CAP, GAP, and SV were 6, 5, and 4, respectively. Moreover, the ED and HE were decreased by 16.78% and 28.68%, while the MRR was enhanced by 89.72%, respectively, as compared to the common setting values. The explored outcome can be employed as a technical solution to enhance the energy efficiency, drilled quality, and productivity of the EDD operation.

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“…Bu gibi handikapların üstesinden gelebilmek için her geçen gün yeni çözümler EEİ yöntemine dahil edilmektedir [24]. Bunlar: dielektrik sıvıya toz katkısı [25], dielektrik sıvıyı ısıtma [26], farklı tipte dielektrik sıvı kullanımı [27], dielektrik sıvı içerisine aşındırıcı madde katkısı [28], döner elektrot kullanımı [29], farklı tipte elektrot kullanımı [30] ve işleme bölgesinde manyetik alan oluşturma [31] olarak örneklendirilebilir. Literatürdeki birçok çalışmada toz katkılı EEİ (TKEEİ) metodunun kullanılmasıyla; İİH'nin arttığı [32], toz parçaların boşalım enerjisini dağıtarak verimliliği artırdığı [33] ve geleneksel EEİ ile işlenmiş parçalara nazaran daha üstün yüzey özelliklerinin sergilendiği [34] rapor edilmiştir.…”

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TiO2 Katkılı Çevre Dostu Dielektrik Sıvının Elektro Erozyon Delik Delme Performanslarının Araştırılması

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2020

Bilecik Şeyh Edebali Üniversitesi Fen Bilimleri Dergisi

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Bu çalışmada iş parçası olarak AISI4140 çeliği, elektrot olarak 2 mm dış çapa sahip ortası tek delik bakır tüp, dielektrik sıvı olarak ise yüksek parlama noktasına ve düşük viskoziteye sahip Eurolub EDM ER100 çevreci tip elektro erozyon sıvısı kullanılmıştır. ER100 içerisine farklı derişim oranlarında (katkısız, 5 g/l ve 10 g/l) katılan TiO 2 tozunun hassas (M1), orta (M2) ve kaba (M3) işleme koşullarında elektro erozyon ile işleme (EEİ) çıktı performansları (iş parçası işleme hızı (İİH), elektrot aşınma hızı (EAH), bağıl aşınma (BA) ve ortalama yüzey pürüzlülüğü (R a )) üzerine etkileri araştırılmıştır. Dielektrik sıvıya 5 g/l TiO 2 tozu katkısı sayesinde her üç işleme tipinde İİH değeri açısından ortalama %30,48'lik bir artış elde edilmiştir. Yine, dielektrik sıvıya 10 g/l TiO 2 tozu katkısıyla her üç işleme tipinde ortalama %57,03'lük bir işleme hızı artışı sağlanmıştır. Elektrotu döndürmek İİH değerleri üzerinde M1 işleme tipinde ortalama %99,5 artış sağlarken, M2 işleme tipinde ortalama %13,75 ve M3 işleme tipinde ortalama %9,38 oranlarında artışlara olanak sağlamıştır. TiO 2 tozu katkısıyla hem sabit hem de döner elektrotla yapılan deneylerde, M1 ve M2 işleme tiplerinde elektrot aşınması azalırken sadece M3 işleme tipinde litreye 10 gram TiO 2 tozu katkılı dielektrikte elektrot aşınmasının arttığı sonucuna varılmıştır. BA değerlerinin tıpkı EAH değerleri gibi özellikler sergilediği tespit edilmiştir. Dielektrik sıvıya 5 g/l TiO 2 tozu katkısı R a değerlerini M1 için %5,27, M2 için %8 ve M3 için %2,95 oranlarında azaltmıştır. Yine, 10 g/l TiO 2 tozu katkısı R a değerlerini M1 için %8,15, M2 için %15,07 ve M3 için %6,21 oranlarında azalttığı tespit edilmiştir.

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Effects of dielectric fluids on surface integrity for the recast layer in high speed EDM drilling of nickel alloy

Cited by 75 publications

References 31 publications

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

Multi-Response Optimization of Electrical Discharge Drilling Process of SS304 for Energy Efficiency, Product Quality, and Productivity

TiO2 Katkılı Çevre Dostu Dielektrik Sıvının Elektro Erozyon Delik Delme Performanslarının Araştırılması

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