Experimental investigation &amp; optimisation of wire electrical discharge machining process parameters for Ni49Ti51 shape memory alloy

Goyal, Ashish; Rahman, Huzef Ur; Ghani, Saiful Anwar Che

doi:10.1016/j.jksues.2020.01.003

Cited by 16 publications

(8 citation statements)

References 19 publications

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“…The discontinuous machining provided electrochemical debris and uneven disintegration of the surface around the hole [23]. The wide craters on the MS were also spotted due to high DE [40]. The higher DE provided more globules, micropores, and microcracks on the MS [41].…”

Section: Surface Analysis Of Drilled Hole At Optimum Parametermentioning

confidence: 99%

Electrochemical arc micro-drilling of Nickel-Titanium SMAs utilizing GRA-based AHP and RSM

KUMAR

Kumar²

2022

Preprint

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Electrochemical arc machining (ECAM) is a hybrid technique which is discovered by the further development of ECDM. As Nickel-Titanium is a hard-to-cut shape memory alloy, therefore ECAM has been utilized. For any manufacturing industry, the machining characteristics are an essential component of the process for the production of NiTi-based things, therefore in this study, MRR, TWR, over cut, and delamination have been chosen as performance parameters whereas voltage, electrolyte concentration (ethanol with ethylene glycol and NaCl), and tool rotation has been selected as variable parameters. The molybdenum has a low tendency to react chemically, therefore it was chosen as a tool for drilling NiTi. The optimum drilling condition has been detected as 20 v/v% of electrolyte concentration, 0 rpm of tool rotation, and 80V of voltage with help of the GRA-based AHP technique, and further, the GRG was optimized by RSM. The optimum value of the performance parameter has been observed as 101.19 mg/min, 0.006 mg/min, 0.111, and 1.16 for MRR, TWR, OC, and delamination respectively. The SEM analysis revealed HAZ, a white layer, melted droplet, number of cavities, craters, and microvoids near the drilled hole. Furthermore, EDX analysis proved that the work surface can be free of Mo after machining Nitinol by electrochemical arc machining. Also, the XRD analysis revealed the development of carbides like TiC in the melting zone of a drilled hole, where that carbide can vanish the shape memory properties in HAZ. As the electrolyte used is a water-free electrolyte, therefore no formation of oxides was observed.

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Section: Surface Analysis Of Drilled Hole At Optimum Parametermentioning

confidence: 99%

Electrochemical arc micro-drilling of Nickel-Titanium SMAs utilizing GRA-based AHP and RSM

KUMAR

Kumar²

2022

Preprint

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“…It was investigated that Ton and Ip have the most significant parameters that affect surface of the shape memory alloy. The multi-objective optimization techniques effectively predicted the response characteristics of wire EDM process [18,19]. Sharma et al [20] studied on wire spark machining of Ni 55.8 by wire EDM process.…”

Section: Introductionmentioning

confidence: 99%

“…The excessive tool wear, burr formation, poor surface finish and more power consumption has been reported during the conventional machining process [25][26][27]. The nitinol SMA's are useful for the biomedical application due to their higher shape-memory strain and good biocompatibility [4,18,29,30]. A literature survey reveals limited work reported to optimize wire EDM process parameters by hybrid optimization techniques.…”

Section: Introductionmentioning

confidence: 99%

Experimental studies on Wire EDM for surface roughness and kerf width for shape memory alloy

Goyal

Rahman

2021

Sādhanā

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The present experimental work was carried out on wire electrical discharge machine (WEDM) over NiTi shape memory alloy for biomedical applications. Improving of machineability of intricate profiles in biomaterial applications is a challenging task. The experiments were performed on WEDM by using a brass wire of 0.25 mm diameter, as tool electrode. A range of 4 to 8 ampere of current, range of 60-120 ls of pulse on time, range of 15-45 ls of pulse off time, range of 11-15 cm 2 /gm of wire tension and range of 4-8 m/min wire feed were selected as input parameters. The influence of these parameters was observed on surface roughness and kerf width during fabrication of rectangular slots. The discharge craters, voids, microcracks and white layer have been observed in machined surface by scanning electron microscopy (SEM). It was observed that at higher values of discharge energy, the recast layer thickness increases. The higher recast layer found is 15.88 at Ip = 8, Ton = 120, Toff = 30, WT = 11, Wf = 4. The performance of responses was analysed by the response surface methodology and artificial neural network modelling. The obtained values of 0.993 and 0.995 from ANN model shows strong correlation between selected parameters. The obtained desirability is 0.957 that presents the developed model and is quite significant for both responses.

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“…Since the last decade, the most active research field is the machining characteristics of advanced alloy material because of their massive demand and hazard issues associated with their machining criteria. 1,2 Ti6Al4V alloy is primarily used to manufacture biomedical parts and aerospace components due to its outstanding mechanical properties. Machining of Ti6Al4V is an immensely challenging task as it attributes high temperatures during the conventional method.…”

Section: Introductionmentioning

confidence: 99%

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Chakraborty

Mitra

Bose

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

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Experimental investigation & optimisation of wire electrical discharge machining process parameters for Ni49Ti51 shape memory alloy

Cited by 16 publications

References 19 publications

Electrochemical arc micro-drilling of Nickel-Titanium SMAs utilizing GRA-based AHP and RSM

Electrochemical arc micro-drilling of Nickel-Titanium SMAs utilizing GRA-based AHP and RSM

Experimental studies on Wire EDM for surface roughness and kerf width for shape memory alloy

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

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