Minimizing the corner errors (top and bottom) at optimized cutting rate and surface finish during WEDM of Al6061

Ishfaq, Kashif; Zahoor, Sadaf; Khan, Sarmad Ali; Rehman, Mudassar; Alfaify, Abdullah; Anwar, Saqib

doi:10.1016/j.jestch.2021.01.008

Cited by 17 publications

(12 citation statements)

References 38 publications

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“…The process improvement in EBM concerning the performance characteristics can be achieved by performing the parametric optimization. This optimization assists in developing the optimal settings of control variables to validate the research the experimental findings as discussed by various researchers (Rehman et al, 2020;Ishfaq et al, 2021;Khan et al, 2021;Zahoor et al, 2021) (Figure 4).…”

Section: Electron Beam Melting Of Medical Titanium Alloysmentioning

confidence: 82%

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Ishfaq

Rehman

Khan

et al. 2021

RPJ

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Purpose Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has significantly emerged the need for artificial implants. Their implantation can act as a substitute for fractured bones or disordered joints. Therefore, this study aims to focus on electron beam melted titanium (Ti)-based orthopaedic implants along with their recent trends in the field. Design/methodology/approach The main contents of this work include the basic theme and background of the metal-based additive manufacturing, different implant materials specifically Ti alloys and their classification based on crystallographic transus temperature (including α, metastable β, β and α + β phases), details of electron beam melting (EBM) concerning its process physics, various control variables and performance characteristics of EBMed Ti alloys in orthopaedic and orthodontic implants, applications of EBMed Ti alloys in various load-bearing implants, different challenges associated with the EBMed Ti-based implants along with their possible solutions. Recent trends and shortfalls have also been described at the end. Findings EBM is getting significant attention in medical implants because of its minor issues as compared to conventional fabrication practices such as Ti casting and possesses a significant research potential to fabricate various medical implants. The elastic modulus and strength of EBMed ß Ti-alloys such as 24Nb-4Zr-8Sn and Ti-33Nb-4Sn are superior compared to conventional Ti for orthopaedic implants. Beta Ti alloys processed by EBM have near bone elastic modulus (approximately 35–50 GPa) along with improved tribo-mechanical performance involving mechanical strength, wear and corrosion resistance, along with biocompatibility for implants. Originality/value Advances in EBM have opened the gateway Ti alloys in the biomedical field explicitly ß-alloys because of their unique biocompatibility, bioactivity along with improved tribo-mechanical performance. Less significant work is available on the EBM of Ti alloys in orthopaedic and orthodontic implants. This study is directed solely on the EBM of medical Ti alloys in medical sectors to explore their different aspects for future research opportunities.

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Section: Electron Beam Melting Of Medical Titanium Alloysmentioning

confidence: 82%

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Ishfaq

Rehman

Khan

et al. 2021

RPJ

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Section: Technical and Engineering Aspects Of The Current Researchmentioning

confidence: 99%

“…However, besides the mentioned advantages, there are various challenges being faced by FDM that limit its use in different practical scenarios. The limitations incurred by FDM are as follows: it takes a long time, especially when the model is complicated; the printed parts exhibit reduced mechanical properties when subjected to severe forces; FDM printed components are not suitable for harsh environments, such as human fluids, high temperatures/pressures and gases; mass or batch manufacturing with FDM is not practical and existing manufacturing processes cannot be completely substituted by 3DP-based production; In FDM, choosing the best processing parameters is anisotropic and the best settings are determined by a variety of factors, such as filament material type and others; Several engineering components, such as shafts, bearings, couplings, pistons, dies, molds and gears, manufactured through usual manufacturing/machining techniques are subject to several issues, such as craters, micro-cracks and excessive material (debris) formation (Rehman et al , 2020; Ishfaq et al , 2021; Khan et al , 2021; Zahoor et al , 2021). While 3DP can only be used to produce parts with no/little deformities and producing critical industrial parts is always remained a difficult task for 3DP; and although 3DP has been used to fabricate substrates, encasings and structural components for nanoparticle resource collecting mechanisms, it is rare to see AM used for large-scale renewable energy systems with electrical output in Watt or kilowatts. …”

Section: Technical and Engineering Aspects Of The Current Researchmentioning

confidence: 99%

“…Several engineering components, such as shafts, bearings, couplings, pistons, dies, molds and gears, manufactured through usual manufacturing/machining techniques are subject to several issues, such as craters, micro-cracks and excessive material (debris) formation (Rehman et al, 2020;Ishfaq et al, 2021;Khan et al, 2021;Zahoor et al, 2021). While 3DP can only be used to produce parts with no/little deformities and producing critical industrial parts is always remained a difficult task for 3DP; and although 3DP has been used to fabricate substrates, encasings and structural components for nanoparticle resource collecting mechanisms, it is rare to see AM used for large-scale renewable energy systems with electrical output in Watt or kilowatts.…”

Section: Technical and Engineering Aspects Of The Current Researchmentioning

confidence: 99%

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Additive manufacturing is sustainable technology: citespace based bibliometric investigations of fused deposition modeling approach

Wang¹,

Mushtaq²,

Ahmed³

et al. 2021

RPJ

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Purpose Additive manufacturing (AM) technology has a huge influence on the real world because of its ability to manufacture massively complicated geometrics. The purpose of this study is to use CiteSpace (CS) visual analysis to identify fused deposition modeling (FDM) research and development patterns to guide researchers to decide future research and provide a framework for corporations and organizations to prepare for the development in the rapid prototyping industry. Three-dimensional printing (3DP) is defined to budget minimize manufactured input and output for aviation and the medical product industrial sectors. 3DP has implemented its potential in the Coronavirus Disease of 2019 (COVID-19) reaction. Design/methodology/approach First, 396 original publications were extracted from the web of science (WOS) with the comprehensive list and did scientometrics analysis in CS software. The parameters are specified in CS including the span (from 2011 to 2019, one year slice for the co-authorship and the co-accordance analysis), visualization (show the merged networks), specific criteria for selection (top 20%), node form (author, organization, region, reference cited; cited author, journal and keywords) and pruning (pathfinder and slicing network). Finally, correlating data was studied and showed the results of the visualization study of FDM research were shown. Findings The framework of FDM information is beginning to take shape. About hot research topics, there are “Morphology,” “Tensile Property by making Blends,” “Use of Carbon nanotube in 3DP” and “Topology optimization.” Regarding the latest research frontiers of FDM printing, there are “Fused Filament Fabrication,” “AM,” in FDM printing. Where “Post-processing” and “environmental impact” are the research hotspots in FDM printing. These research results can provide insight into FDM printing and useful information to consider the existing studies and developments in FDM researchers’ analysis. Research limitations/implications Despite some important obtained results through FDM-related publications’ visualization, some deficiencies remain in this research. With >99% of articles written in English, the input data for CS was all downloaded from WOS databases, resulting in a language bias of papers in other languages and neglecting other data sources. Although, there are several challenges being faced by the FDM that limit its wide variety of applications. However, the significance of the current work concerning the technical and engineering prospects is discussed herein. Originality/value First, the novelty of this work lies in describing the FDM approach in a Scientometric way. In Scientometric investigation, leading writers, organizations, keywords, hot research and emerging knowledge points were explained. Second, this research has thoroughly and comprehensively examined the useful sustainability effects, i.e. economic sustainability, energy-based sustainability, environmental sustainability, of 3DP in industrial development in qualitative and quantitative aspects by 2025 from a global viewpoint. Third, this work also described the practical significance of FDM based on 3DP since COVID-19. 3DP has stepped up as a vital technology to support improved healthcare and other general response to emergency situations.

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“…Thermal energy generated during the process creates excessive temperature sparks [16]. These high-temperature sparks are then used to erode material by melting and vaporization [17]. The generation of higher temperature between tool and base material creates several defects on the machined surfaces, poor surface quality, debris deposition, formation of cracks and pores, and the development of recast layer thickness (RLT) [18,19].…”

Section: Introductionmentioning

confidence: 99%

Effect of Multi-walled carbon nanotubes on the performance evaluation of Nickel-based super-alloy–Udimet 720 machined using WEDM process

Chaudhari¹,

Ayesta

Doshi³

et al. 2022

Preprint

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The diverse capabilities of nickel-based super-alloy (Udimet 720), like robust mechanical strength, ductility, resistance to excessive temperature deformation, and advanced corrosion and oxidation resistance, make it suitable for use in multiple applications. These super-alloys are identified as extremely difficult materials for machining to meet feature and manufacturing requirements. In the present work, we demonstrated the machining of Udimet 720 by employing the wire-electrical discharge machining (WEDM) technique. Pulse-on-time (Ton), Pulse-off-time (Toff), current, and MWCNT amount were preferred as input variables. The effect of selected design variables was studied on material removal rate (MRR), surface roughness (SR), and recast layer thickness (RLT). Box Behnken design was utilized to design an experimental matrix. For statistical analysis, analysis of variance (ANOVA) was employed. From ANOVA, the current had the highest contributor with 35.85% to affect MRR, while MWCNT amount was found to be the highest contributor for deciding the values of both SR and RLT with contributions of 42.66% and 40.07%, respectively. The addition of MWCNT at 1 g/L has substantially improved MRR from 0.8546 g/min to 1.2199 g/min, SR reduced from 5.88 µm to 2.98 µm, and reduction in RLT from 17.8 µm to 11.61 µm. The passing vehicle search (PVS) algorithm was implemented, and the results of single-objective optimization presented the largest MRR of 1.8883 g/min, least SR of 1.89 µm, and least RLT of 9.70 µm. Additionally, a set of non-dominated solutions was obtained through Pareto optimal fronts. A small acceptable deviation was detected among the actual and forecasted results from PVS algorithm. It clearly reveals the acceptance of the PVS technique in the present study for Udimet 720. Lastly, the significance of MWCNT amount on surface textures was revealed by employing scanning electron microscopy (SEM).

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Minimizing the corner errors (top and bottom) at optimized cutting rate and surface finish during WEDM of Al6061

Cited by 17 publications

References 38 publications

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Additive manufacturing is sustainable technology: citespace based bibliometric investigations of fused deposition modeling approach

Effect of Multi-walled carbon nanotubes on the performance evaluation of Nickel-based super-alloy–Udimet 720 machined using WEDM process

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