Investigation on tool wear rate of brass tool during machining of Monel 400 alloy using electric discharge machine

Mahalingam, Manikandan; Varahamoorthi, R.

doi:10.1016/j.matpr.2020.02.244

Cited by 5 publications

(3 citation statements)

References 8 publications

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“…Apparently, L6 gave the best MRR value too. Similar kind of trend was observed in results of MRR, Ra, recast layer thickness, and tool wear rate in the previously conducted research on wire EDM process [18][19][20][21][22][23].…”

Section: Wedm Influence On Mrr R a Recast Layer And Toolsupporting

confidence: 88%

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Samson

Sridhar

Ranjith

et al. 2022

Advances in Materials Science and Engineering

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Ti-6Al-4V is known for its lightweight, high tensile strength, exceptional corrosion resistance, and low thermal coefficient of expansion due to which it finds its application in precision surgical instruments and aeronautical and marine engine parts. In this study, Ti-6Al-4V has been machined using wire EDM machine with two different wire materials. The wire thickness of 0.25 mm heat-treated brass and zinc-coated brass tool and super cool oil as dielectric fluid were utilized for the machining process. Taguchi L9 orthogonal array was used. Ton (Pulse ON time), Toff (Pulse OFF time), wire feed, and Ip (Current) were the input parameters, and the response parameters such as surface roughness (Ra), material removal rate (MRR), tool wear rate (TWR), and recast layer thickness were optimized by TOPSIS optimization. From the results, higher tool wear rate was observed in brass tool. The titanium percentage after machining was found to be 55.05% for zinc-coated brass wire, whereas it was 51.58% for brass wire. Better productivity and surface integrity were observed in zinc-coated brass tool compared to heat-treated brass. MRR increased to 54.93%, surface roughness decreased to 2.40%, recast layer thickness increased to 3.44%, and tool wear rate was increased to 47.96%.

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Section: Wedm Influence On Mrr R a Recast Layer And Toolsupporting

confidence: 88%

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Samson

Sridhar

Ranjith

et al. 2022

Advances in Materials Science and Engineering

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show abstract

“…Advanced machining processes such as electric discharge machining (EDM) and wire EDM [8][9][10][11][12], Electrochemical machining (ECM) [13,14], and laser and plasma machining [15][16][17][18][19][20] were also used in machining Monel-400. For example, WEDM was used by Kumar et al [8].…”

Section: Introductionmentioning

confidence: 99%

“…The results obtained found that Monel-400 produced better results in terms of surface quality of the machine feature than other superalloys. EDM was used by Mahalingam and Varahamoorthi [10] for machining Monel-400. The peak current and the pulse off-time have been found to have a significant impact on tool wear.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Heat Annealing and Parametric Optimization for Drilling of Monel-400 Alloy

Abdo,

Almuzaiqer,

Noman

et al. 2023

JMMP

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A nickel-based copper alloy known as Monel-400 is extensively applied in many industries including aerospace, marine engineering, and nuclear power generation, owing to its exceptional characteristics such as extreme tensile strength and toughness, excellent corrosion resistance, and the ability to retain shape even at extremely high temperatures. Traditional methods of drilling Monel-400 alloy are difficult due to quick tool wear and poor surface polishing, resulting in expensive machining costs. In this study, a technique called heat annealing was implemented to externally heat-treat the Monel-400 alloy material before the drilling process. Cutting force, surface roughness, and tool wear were used as the responses to investigate the effect of heat annealing and the drilling parameters on the machinability of Monel-400. The results revealed that the cutting force (Fz) and surface roughness (Ra and Rt) could be reduced by 33%, 31%, and 25%, respectively, after annealing at 700 °C compared to the results of the drilled Monel-400 at room temperature. It can be observed that the maximum improvement can reach 42% of Fz, 35% of Ra, and 59% of Rt while annealing Monel-400 at 1000 °C. A significant reduction was observed in the tool wear for machining the annealed material, which minimized the tooling and overall machining cost. Regarding the effects of the drilling process on the considered responses, the results revealed that the spindle speed has a greater effect on the cutting force, whereas the feed rate has the most significant effect on Ra. The significance of the drilling input parameters on the outputs is determined by analysis of the main effect plots and surface plots. Subsequently, the multi-objective genetic algorithm (MOGA) is used to identify the optimal parametric conditions for minimizing the cutting force and surface roughness of the drilled holes. The optimized values achieved via multi-objective optimization are the cutting force, Fz = 388–466 N, and the surface roughness, Ra = 0.17–0.19 μm and Rt = 3–3.5 μm, respectively.

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Machining of Smart Materials Using Electric Discharge Machining: A Review

Singh¹,

Sarangi²

2023

Lecture Notes in Mechanical Engineering

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Investigation on tool wear rate of brass tool during machining of Monel 400 alloy using electric discharge machine

Cited by 5 publications

References 8 publications

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Investigation of Heat Annealing and Parametric Optimization for Drilling of Monel-400 Alloy

Machining of Smart Materials Using Electric Discharge Machining: A Review

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