Influence of energy fraction in EDM drilling of Inconel 718 by statistical analysis and finite element crater-modelling

Kliuev, Mikhail; Florio, Kevin; Akbari, Mansur; Wegener, Konrad

doi:10.1016/j.jmapro.2019.03.002

Cited by 53 publications

(23 citation statements)

References 26 publications

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“…The machined alloy sample as per the parametric settings of trial 9, demonstrates the highest material removal rate (39.4 ± 0.98 mm 3 /min). These results are in accordance with previously reported studies, where researchers reported discharge current, pulse-on duration, dielectric type and electrode material as the most significant factors for the EDM performance affecting the output responses [ 33 , 34 , 35 ]. The optimum parameters for maximum material removal rate of DSS substrates were examined from the S/N ratios plot ( Figure 2 ) as 16 A of current, P-on = 150 µs, P-off = 60 µs, and use of W-Cu electrode in EDM oil.…”

Section: Resultssupporting

confidence: 93%

Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel

et al. 2020

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The present article focused on the surface characterization of electric discharge machined duplex stainless steel (DSS-2205) alloy with three variants of electrode material (Graphite, Copper-Tungsten and Tungsten electrodes). Experimentation was executed as per Taguchi L18 orthogonal array to inspect the influence of electric discharge machining (EDM) parameters on the material removal rate and surface roughness. The results revealed that the discharge current (contribution: 45.10%), dielectric medium (contribution: 18.24%) majorly affects the material removal rate, whereas electrode material (contribution: 38.72%), pulse-on-time (contribution: 26.11%) were the significant parameters affecting the surface roughness. The machined surface at high spark energy in EDM oil portrayed porosity, oxides formation, and intermetallic compounds. Moreover, a pin-on-disc wear analysis was executed and the machined surface exhibits 70% superior wear resistance compared to the un-machined sample. The surface thus produced also exhibited improved surface wettability responses. The outcomes depict that EDMed DSS alloy can be considered in the different biomedical and industrial applications.

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Section: Resultssupporting

confidence: 93%

Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel

et al. 2020

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“…The accumulation of debris and bubbles at the hole bottom decreases the process performance and worsens the hole accuracy. An accumulation of eroded particles at the hole bottom can create a debris chain [26]. Debris chains are more difficult to remove from the gap area.…”

Section: Influence Of the Inlet Dielectric Fluid Pressure And The Toomentioning

confidence: 99%

“…When the discharge ends, the plasma collapses, and the material is then ejected. The rapid cooling during the pulse-off time leads to the formation of spherical debris, a typical shape that is obtained when a liquid is rapidly solidified [26][27][28].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Machinability of the Inconel 718 Superalloy during the Electrical Discharge Drilling Process

Machno

2020

Materials

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The properties of the Inconel 718 superalloy are used in the manufacturing of aircraft components; its properties, including high hardness and toughness, cause machining difficulties when using the conventional method. To circumvent this, non-conventional techniques are used, among which electrical discharge machining (EDM) is a good alternative. However, the nature of removing material using the EDM process causes the thermophysical properties of Inconel 718 to hinder its machinability; thus, a more extensive analysis of the influence of these properties on the EDM process, and a machinability analysis of this material in a wider range, using more process parameters, are required. In this study, we investigated the drilling of micro-holes into the Inconel 718 superalloy using the EDM process. An experiment was conducted to evaluate the impact of five process parameters with a wide range of values (open voltage, time of the impulse, current amplitude, the inlet dielectric fluid pressure, and tube electrode rotation) on the process’s performance (drilling speed, linear tool wear, the side gap thickness, and the aspect ratio of holes). The analysis shows that the thermal conductivity of this superalloy significantly influences the effective drilling of holes. The combination of a higher current amplitude (I ≥ 3.99 A) with an extended pulse time (ton ≥ 550 µs) can provide a satisfactory hole accuracy (side gap thickness ≤ 100 µm), homogeneity of the hole entrance edge without re-solidified material, and a depth-to-diameter ratio of about 19. Obtaining a high dimensional shape accuracy of holes has an enormous effect on their usability in the structure of the components in the aviation industry.

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“…However, nickel-based superalloys are hard to machine due to the low thermal conductivity and high temperature strength [4,5], which could cause poor surface quality, serious tool wear, and low productivity in traditional machining [6][7][8]. As for a few non-traditional machining methods, laser machining [9,10] and electrical discharge machining (EDM) [11,12] which based on heat melting usually produce micro cracks, recast layers, and heat affected zones, while electrochemical machining (ECM) [13] could not meet the demands of high precision machining due to stray current corrosion.…”

Section: Introductionmentioning

confidence: 99%

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

et al. 2020

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Electrochemical grinding (ECG) technique composed of electrochemical machining (ECM) and mechanical grinding is a proper method for machining of difficult-to-cut alloys. This paper presents a new ultrasonic assisted electrochemical drill-grinding (UAECDG) technique which combines electrochemical drilling, mechanical grinding, and ultrasonic vibration to fabricating high-quality small holes on superalloy. By applying ultrasonic vibration to high-speed rotating electrode in ECG, machining stability, efficiency, and surface quality can be obviously improved. Firstly, the electrochemical passive behavior of superalloy is studied, the mathematical model and simulation of gap electric field are established. Then, several experiments are conducted to investigate the influence of applied voltage, feed rate and ultrasonic amplitude on the machining quality. The balance of material removal between electrochemical reaction and mechanical grinding is achieved by optimizing the machining parameters. It reveals that the surface quality as well as machining stability and efficiency can be significantly improved by applying rotating ultrasonic vibration to the ECG process. Finally, several small holes of high quality have been machined successfully along with surface roughness of hole sidewall decreases from Ra 0.99 μm to Ra 0.14 μm by UAECDG.

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Influence of energy fraction in EDM drilling of Inconel 718 by statistical analysis and finite element crater-modelling

Cited by 53 publications

References 26 publications

Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel

Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel

Investigation of the Machinability of the Inconel 718 Superalloy during the Electrical Discharge Drilling Process

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

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