Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

Chaudhary, Tina; Siddiquee, Arshad Noor; Chanda, Arindam Kumar; Abidi, Mustufa Haider; Al-Ahmari, Abdulrahman

doi:10.1177/1687814020967580

Cited by 8 publications

(3 citation statements)

References 48 publications

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“…The surface roughness reduces from 500 rpm to 1000 rpm, and after that increases with a rise in speed, which is due to the developed wear on a machined surface with high spindle speed [65,66]. The surface roughness increased with feed rate due to strain hardening effect while machining with a higher feed rate [67,68]. Surface roughness is also enhanced with a higher depth of cut due to large volume removal from the surface, which generates the rough surface of the machined sample.…”

Section: Resultsmentioning

confidence: 99%

Archive of Mechanical Engineering

Kharwar

Verma

Mandal

et al. 2020

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In manufacturing industries, the selection of machine parameters is a very complicated task in a time-bound manner. The process parameters play a primary role in confirming the quality, low cost of manufacturing, high productivity, and provide the source for sustainable machining. This paper explores the milling behavior of MWCNT/epoxy nanocomposites to attain the parametric conditions having lower surface roughness (Ra) and higher materials removal rate (MRR). Milling is considered as an indispensable process employed to acquire highly accurate and precise slots. Particle swarm optimization (PSO) is very trendy among the nature-stimulated metaheuristic method used for the optimization of varying constraints. This article uses the non-dominated PSO algorithm to optimize the milling parameters, namely, MWCNT weight% (Wt.), spindle speed (N ), feed rate (F), and depth of cut (D). The first setting confirmatory test demonstrates the value of Ra and MRR that are found as 1.62 µm and 5.69 mm 3 /min, respectively and for the second set, the obtained values of Ra and MRR are 3.74 µm and 22.83 mm 3 /min respectively. The Pareto set allows the manufacturer to determine the optimal setting depending on their application need. The outcomes of the proposed algorithm offer new criteria to control the milling parameters for high efficiency.

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Section: Resultsmentioning

confidence: 99%

Archive of Mechanical Engineering

Kharwar

Verma

Mandal

et al. 2020

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“…al. (36) studied the WEDM, which was used to manufacture nimonic alloy tiny gears. The effects of wire tension, T ON , and dielectric fluid on the variables of response were also investigated.…”

Section: Materials Removal Ratementioning

confidence: 99%

WEDM Process Parameters Analysis and Optimization: A REVIEW

Anwar,

Shather,

Khudhir

2024

Salud, Ciencia y Tecnología - Serie de Conferencias

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Wire Electrical Discharge Machining (WEDM) represents a non-conventional machining approach that harnesses thermal electrical energy for the fabrication of intricate structures. WEDM machines excel in achieving precise dimensions and a polished surface finish. It finds frequent application in the machining of robust materials that pose challenges for conventional manufacturing methods due to issues like vibrations. Within this machining method, numerous process parameters and performance indicators come into play, prompting various studies and investigations into its intricacies. This paper presents a comprehensive overview of current research trends in WEDM, particularly focusing on parameters for enhancing performance, such as surface roughness (SR), material removal rate (MRR), and Kerf width (KW). Notably, several process parameters, including pulse-off-time (TOFF), servo voltage (SV), pulse-on-time (TON), peak current (I), and wire tension (WT), contribute to the WEDM process. Additionally, various optimization techniques like the Taguchi method, Grey Relation Analysis (GRA), and analysis of variance (ANOVA) are employed across diverse materials, encompassing alloys, superalloys, and composites. The findings of this study suggest the importance of considering various process parameters, such as pulse-off-time (TOFF), servo voltage (SV), pulse-on-time (TON), peak current (I), and wire tension (WT), in the WEDM process. Moreover, the application of optimization techniques like the Taguchi method, Grey Relation Analysis (GRA), and analysis of variance (ANOVA) is recommended. These recommendations aim to improve the understanding and optimization of WEDM processes, especially when applied to diverse materials, including alloys, superalloys, and composites.

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“…The comparative analysis revealed that the Bee Colony Cuckoo Search optimization method was superior to RSM. Chaudhary et al [119] analyzed the process parameters of WEDM viz., IP, T off , T on , wire tension, and dielectric fluid on the responses viz., SR, machining time, MRR, kerf width, surface micro-hardness, and depth of microhardness using Entropy-TOPSIS and Pareto ANOVA techniques. It was concluded from the analysis that dielectric fluid (60% of demineralized water + 40% Ethelene glycol), IP 3 A, T off 2 ms, wire tension 6 N, and T on 15 ms were the optimum values of influencing parameter (in the order) for better machining performance.…”

Section: Singh and Misramentioning

confidence: 99%

A review on conventional and nonconventional machining of Nickel-based Nimonic superalloy

Prasad

G.S

2023

Manufacturing Rev.

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Superalloys have gained prominence in recent years in various sectors, namely, spacecraft, marine, power, defense, vehicular and others, due to their ability to withstand high temperatures of up to 980 °C without deformation. Nimonics are Nickel-based superalloys usually known to be hard-to-machine materials due to their high strength at high temperatures, higher hardness, low thermal conductivity, and tendency to react with tool material. All these factors increase the level of difficulties in the machining of Nimonic superalloys. Numerous studies have examined various facets of machining of Nimonic alloys. This article summarizes the observation from 152 research articles to offer a reasonable engineering overview of the study of Nimonic alloys. An overview of Nimonic superalloys and their applications is given first. Then, various conventional and non-conventional machining processes, problems associated with multiple machining processes and methods to rectify the issues concerning the machining process have been reported. Thus, this summary will certainly help industrialists and academic researchers for further research work in machining Nimonic alloys.

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Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

Cited by 8 publications

References 48 publications

Archive of Mechanical Engineering

Archive of Mechanical Engineering

WEDM Process Parameters Analysis and Optimization: A REVIEW

A review on conventional and nonconventional machining of Nickel-based Nimonic superalloy

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