Modeling and Optimization of Machining Nimonic C-263 Superalloy using Multicut Strategy in WEDM

Mandal, Amitava; Dixit, Amit Rai; Das, Alok Kumar; Mandal, Niladri

doi:10.1080/10426914.2015.1048462

Cited by 95 publications

(42 citation statements)

References 19 publications

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“…In this method, the translation of each response is carried out on a common scale. The desirability function ranges from 0 to 1 [30]. Therefore, the response feedback 'xi' is translated In this experiment, desirability is to get the maximum hardness and minimum wear of the coating.…”

Section: Desirability Testmentioning

confidence: 99%

A Novel Method of Laser Coating Process on Worn-Out Cutter Rings of Tunnel Boring Machine for Eco-Friendly Reuse

et al. 2020

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Cutter rings form an integral part of tunnel boring machines (TBM). These cutters are deployed in various hard rock tunneling projects. The life of the cutter rings governs the economics of tunneling significantly. This paper presents a novel methodology to enhance hardness and wear resistance of used worn out disc cutters in TBM for eco-friendly reuse. Disc cutters are mainly made of H13 tool steel. To improve the hardness and wear resistance, a layer of tungsten carbide is coated on the used cutter rings. Considering the long operating hours of TBM, cutter rings get worn out due to severe interaction with the hard rock both in compression and rolling mode. Replacement of the cutter-ring is costly, and quite a time consuming and cumbersome job. Refurbishment is always a better option and laser cladding is a novel technique for enhanced life of cutters. It increases the hardness and wear resistance of the cutters to a considerable extent. Cladding is carried out with the help of a laser beam. In this method, a layer of nanoparticles of tungsten carbide powder is deposited on the worn-out surface of the cutters. For carrying out the investigation, different coating parameters are selected based on the central composite design (CCD). With different capacities of laser, a total of 13 samples were prepared at various scanning speeds varying between 200 to 300 mm/min and a level of laser power varying between 100 to 200 W. The coating is critically inspected by various means such as an optical microscope, FESEM, and EDS. Hardness testing was accomplished by Vicker’s hardness testing machine. Wear testing was carried out with the aid of pin on disc setup. The results shows an asymmetrical behavior between the yield parameters (hardness and wear rate) and process parameters (scanning speed and laser power). The hardness values increased from 16% to 95%. A correlation test was conducted between the hardness and wear rate. The results depict a clear negative correlation between them, indicating the advantage of laser coating for reducing cutter ring wear in TBM.

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Section: Desirability Testmentioning

confidence: 99%

A Novel Method of Laser Coating Process on Worn-Out Cutter Rings of Tunnel Boring Machine for Eco-Friendly Reuse

et al. 2020

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“…In a study of Ti6Al4V alloy cut with WEDM; when the values of Ton, Toff, I, Va, fw and tw increase, the cutting width is increased and also the increment of Ton, Va, water pressure and fw increase the MRR is declared [11]. In a study in which statistical analysis and experimental studies were evaluated together, it was emphasized that the most effective parameters on MRR and Ra are discharge current and T on [12][13][14][15][16]. The thermophysical properties of the workpiece, plays a important role in affecting the EDM process.…”

Section: Introductionmentioning

confidence: 99%

Optimization of machining performance parameters in wire EDM of metals with different thermophysical properties

Özerkan¹

2019

Balıkesir Üniversitesi Fen Bilimleri Enstitüsü Dergisi

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CNC Wire electric discharge machining (WEDM) is different mode of electro discharge machining (EDM) in which conductive, stretched small diameter thin wire is used as tool. It has been widely used to shape machine elements by electrical sparks. In cutting with WEDM, suitable input parameters for the work piece material should be selected due to the its specifications. However the desired machining performace outputs like material removal rate (MRR) and surface roughness (Ra) parameters can be controlled in this way. In this study the role of thermophysical properties of work piece materials are researched in WEDM. And also, in this presented study an attempt has been made to Grey relational analysis to obtain desirable performance characteristics through the selection of appropriate process parameters. For this purpose, aluminum, copper and high speed steel (HSS) are machined with various parameters. As a result, the greatest MRR was obtained in the cutting of copper and in HSS and aluminum processes, respectively. And also if the detected surface roughness values are evaluated from lowest to highest copper, HSS and aluminum metals, respectively.

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“…Mandal et al [12] have used the Response surface methodology (RSM) for optimization of machining parameters in wire electric-discharge machining of Nimonic C-263 superalloy. They have found that the cutting rate is significantly influenced by pulse on time, pulse off time and servo reference voltage.…”

Section: Introductionmentioning

confidence: 99%

Grey relational analysis-based genetic algorithm optimization of electrical discharge drilling of Nimonic-90 superalloy

Pandey

Gautam

2018

J Braz. Soc. Mech. Sci. Eng.

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Nickel-based superalloys are being increasingly used in aerospace, automotive industries due to their excellent thermomechanical properties. These applications require complex shapes and profiles which may not be obtained by conventional machining processes. These materials are also known as difficult-to-machine due to their excellent thermo-mechanical properties. The electrical discharge drilling proves its suitability in the precision drilling of superalloys. During, the electrical discharge drilling of these materials, hole taper, hole circularity and hole dilation are key attributes which influence the drilled hole quality. In this research paper, the experiments have been conducted by L 27 orthogonal array and this experimental data have been utilized for developing the models of different geometrical quality characteristics such as hole circularity, hole taper and hole dilation. Further, a new hybrid approach grey relational analysis-based genetic algorithm has been proposed and implemented for the multi-objective optimization of different quality characteristics. The effects of different process parameters on various geometrical quality characteristics have also been discussed. Finally, the confirmation tests have been performed to validate the predicted results obtained by the proposed hybrid methodology to the experimental results. It has been observed by the comparison results that the machining performance in the electrical discharge drilling process has been remarkably improved through proposed approach. Keywords Electrical discharge drilling Á Nimonic-90 Á Multi-objective optimization Á Hole taper Á Hole circularity and dilation Á Grey relational analysis-based genetic algorithm (GRGA)

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Modeling and Optimization of Machining Nimonic C-263 Superalloy using Multicut Strategy in WEDM

Cited by 95 publications

References 19 publications

A Novel Method of Laser Coating Process on Worn-Out Cutter Rings of Tunnel Boring Machine for Eco-Friendly Reuse

A Novel Method of Laser Coating Process on Worn-Out Cutter Rings of Tunnel Boring Machine for Eco-Friendly Reuse

Optimization of machining performance parameters in wire EDM of metals with different thermophysical properties

Grey relational analysis-based genetic algorithm optimization of electrical discharge drilling of Nimonic-90 superalloy

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