Enhancing low-speed WEDM machining capabilities on Nitronic-50 with a constant frequency ultrasonic hybrid method

Abstract

Nitronic-50 stainless steel is a high-strength and corrosion-resistant austenitic premium steel. It requires improved surface characteristics due to its wide use in various applications like fasteners, marine hardware, hydroelectric-power turbines, pressure vessels, etc. This work focuses on machining hard-to-machine Nitronic-50 steel is unconventionally machined using constant frequency ultrasonic-aided low-speed wire electrical discharge machining (USV-LS-WEDM) to enhance its machined surface integrity. This method achieves effective results when cutting high-strength materials with intricate shapes. Material removal rate (MRR) and surface roughness (Ra) were measured by considering inputs such as servo voltage (SV), pulse off time ( Toff), pulse on time ( Ton) and current (I) with an ultrasonic-vibration range of 20,000 Hz. The appropriate selection and usage of LS-WEDM parameters is a challenging process and is done with parametric analysis. The MRR of Nitronic-50 was enhanced with an increase in Ton and I along with a reduction in Toff and SV. Surface roughness (Ra) decreased with a gradual reduction in Ton, I, and an increase in SV. The USV-WEDM was compared with a stand-alone WEDM indicating that the MRR for USV-WEDM was improved by 12% and the Ra was decreased by 9% due to effective distribution of spark discharges, which increased material erosion and redistribution of molten metal characteristics. Machining quality for hard-to-machine Nitronic-50 steel was certainly enhanced via hybrid ultrasonic vibration with the existing LS-WEDM.

Fiber Laser Cutting of AISI 431 Martensitic Stainless Steel: An Experimental Investigation

“…W 1 and W 2 refer to the initial weight and final weight of the laser-cut sample, and AISI 431 density (ρ) = 7.80 g/cm 3 and the machining time was noted as 't' in minutes. The Ra was measured using the tester SJ-210.…”

“…Our experiment involves fiber laser cutting AISI 431 martensitic stainless steel. Response surface methodology with Box-Behnken design (RSM-BBD) optimization is adopted to identify the optimized cutting parameters [3]. Additionally, we conducted microhardness measurements and scanning electron microscope (SEM) analysis to scrutinize the resultant microstructure and mechanical properties of AISI 431 stainless steel.…”

An Experimental Evaluation of the Cutting Capability of SS 431 Steel Using Abrasive Water Jet Machining (AWJM)

“…The study systematically explored the key process parameters influencing machining performance, including abrasive water pressure, standoff distance, and traverse rate. Response surface methodology (RSM-BBD) was adopted to optimize these parameters effectively, allowing for robust and efficient parameter setting that enhanced machining efficiency while preserving material integrity [4]. The findings of this study promise to contribute significantly to the advancement of precision cutting technologies and the utilization of SS 431 steel in diverse industrial sectors.…”

Wire EDM Process of AISI 431 Martensitic Stainless Steel: A Machinability Investigation

“…This investigation presents the optimal process parameters for machining AISI 451 alloys to achieve higher material removal with good surface quality. AISI 451 alloys are machined using the RSM-BBD optimization technique as part of the wire EDM process [4]. An SEM analysis was used to characterize the machined surface, and the hardness variation in the machined alloy was measured using the micro-Vicker.…”