Machinability Analysis and Optimization in Wire EDM of Medical Grade NiTiNOL Memory Alloy

Kulkarni, Vinayak N.; Gaitonde, V. N.; Karnik, S.R.; Manjaiah, M.; Davim, J. Paulo

doi:10.3390/ma13092184

Cited by 36 publications

(19 citation statements)

References 16 publications

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“…Deb et al [ 19 ] investigated the influence of the peak current, pulse on time, and pulse off-time on the cutting speed, average surface roughness, total surface roughness, kerf width, and wire wear in Inconel 800 electrical discharge machining. Kulkarni et al [ 20 ] investigated the machinability of NiTiNOL alloy in the WEDM process. Mouralova et al [ 21 ] investigated the possibility of using WEDM for machining High-Entropy Alloys (HAE).…”

Section: Introductionmentioning

confidence: 99%

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

et al. 2021

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Servicing aircraft engines sometimes requires manufacturing only a single piece of a given part. Manufacturing a turbine disc using traditional methods is uneconomical. It is necessary to use a different machining method recommended for small lot production. One of the proposed methods is WEDM (wire electrical discharge machining). The article presents the results of the research on finishing WEDM of Inconel 718 turbine disc fir tree slots. The influence of infeed, mean gap voltage, peak current, pulse off-time, and discharge energy on the shape accuracy, surface roughness, microcracks, and the white layer thickness were determined. Mathematical models were developed based on the DoE (Design of Experiment) analysis. The statistical significance of the models was verified with the ANOVA (Analysis of Variance) test. The machining parameters control methods that allow achieving the required shape accuracy, surface roughness, and surface layer condition were presented. The obtained surface roughness was Ra = 0.84 μm, the shape accuracy of the slot in the normal-to-feed direction was Δd = 0.009 μm, the profile shape accuracy was Δr = 0.033 μm, and the thickness of recast (white) layer was approximately 5 μm.

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Section: Introductionmentioning

confidence: 99%

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

et al. 2021

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“…Due to the functional properties of nitinol SMAs, their biomedical application has proven successful by increasing the possibility as well as the performance quality of minimally invasive surgeries. The nickel-titanium SMA is highly biocompatible, which makes it useful in orthopedic implants, surgical instruments, cardiovascular devices, and orthodontic devices [6,7]. Nitinol SMA is categorized into two different types, namely shape memory and superelastic.…”

Section: Introductionmentioning

confidence: 99%

Effect of WEDM Process Parameters on Surface Morphology of Nitinol Shape Memory Alloy

et al. 2020

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Nickel–titanium shape memory alloys (SMAs) have started becoming popular owing to their unique ability to memorize or regain their original shape from the plastically deformed condition by means of heating or magnetic or mechanical loading. Nickel–titanium alloys, commonly known as nitinol, have been widely used in actuators, microelectromechanical system (MEMS) devices, and many other applications, including in the biomedical, aerospace, and automotive fields. However, nitinol is a difficult-to-cut material because of its versatile specific properties such as the shape memory effect, superelasticity, high specific strength, high wear and corrosion resistance, and severe strain hardening. There are several challenges faced when machining nitinol SMA with conventional machining techniques. Noncontact operation of the wire electrical discharge machining (WEDM) process between the tool (wire) and workpiece significantly eliminates the problems of conventional machining processes. The WEDM process consists of multiple input parameters that should be controlled to obtain great surface quality. In this study, the effect of WEDM process parameters on the surface morphology of nitinol SMA was studied using 3D surface analysis, scanning electron microscopy (SEM), and energy-dispersive X-ray (EDX) analysis. 3D surface analysis results indicated a higher value of surface roughness (SR) on the top of the work surface and a lower SR on the bottom portion of the work surface. The surface morphology of the machined sample obtained at optimized parameters showed a reduction in microcracks, micropores, and globules in comparison with the machined surface obtained at a high discharge energy level. EDX analysis indicated a machined surface free of molybdenum (tool electrode).

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“…The EDM process removes material by pulsed spark discharge, is not restricted by the strength and hardness of materials, and it does not have direct physical contact with micro cutting tools, which is different from turning or grinding methods, so the noncontact machining nature makes it more competent to fabricate micro cutting tools [ 26 , 27 , 28 ]. In this study, the LS-WEDM (low speed wire electrical discharge machining) tool CA20 (Beijing, China) made by Beijing Agiecharmilles combining with the precise rotating unit was applied to fabricate two groups of micro end mills, namely MT-HMEM (helical micro end mills with micro texture) and HMEM (helical micro end mills).…”

Section: Methodsmentioning

confidence: 99%

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

et al. 2020

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Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the Sa and Sq can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.

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Machinability Analysis and Optimization in Wire EDM of Medical Grade NiTiNOL Memory Alloy

Cited by 36 publications

References 16 publications

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

Effect of WEDM Process Parameters on Surface Morphology of Nitinol Shape Memory Alloy

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

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