Optimization of EDM process parameters in machining Si3N4–TiN conductive ceramic composites to improve form and orientation tolerances

Selvarajan, L.; Narayanan, C. Sathiya; Jeyapaul, R.; Manohar, M.

doi:10.1016/j.measurement.2016.05.018

Cited by 67 publications

(20 citation statements)

References 22 publications

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“…Hinduja et al [73] developed a heat transfer model to examine the behavioral variation of surface property with the change in flushing pressure and speed. Selvarajan et al [74] assessed the surface integrity and accuracy of EDM operation of Si 3 N 4 -TiN ceramic with copper electrode and observed improved surface features with reduced value of pressure. But less dielectric pressure reduces the MRR significantly, so increased discharge energy, moderate spark gap, and suitable flushing pressure can ensure better MRR and impressive surface integrity.…”

Section: Flushing Pressurementioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

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Low removal rate, high power consumption, and dependency on conventional fuels (kerosene as a dielectric) are some premier issues that keep the sustainability index of EDM low, though it has huge acceptability and popularity mostly in aviation sectors and biomedical instrumentation to machine some extensively hard ferrous and nonferrous metal/metal alloys. Besides these, the thermal agitation inside the fusion/machining zone partially burns the dielectrics and tool-workpiece-metal, which evolve some oxides/monoxides. These evolved gases promote an unhygienic breathing atmosphere, which is very much harmful to the operator's health. Sometimes because of inadequate flushing pressure and velocity, carbon particles deposited inside the crater makes the spark unstable and releases carbon monoxide when the temperature exceeds its melting point. According to ISO 14000, every manufacturing process must be comprised of the sustainability criteria, which maintains a compromised balance between the economic, environmental, and social aspects, including the issue of the operator's health. But in real practices, it is very tough to maintain a stoichiometric balance between all these constraints. The article intensely focuses on the issue of emergence of gases during machining and tries to promote the utility of some alternative vegetable oil-based dielectrics, which are experimentally justified as a potent alternative of conventional kerosene. Apart from these, it includes some comparative talks on dielectric nature and their impacts on the responses and surface properties. Finally, this article highlights some compromise solutions which are probably capable of mitigating the hurdles to some extent, so that the sustainable machining can be encouraged in real sense.

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Section: Flushing Pressurementioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

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“…El-Taweel and Hewidy [21] have recommended the use of a planetary EDM for achieving better surface finish and dimensional accuracy at reduced machining time. A few studies report parametric investigations on the proposed model followed by finding the best machining condition for the process while machining workpieces like AISI D2 steel, metal matrix and ceramic composite with copper electrode [22][23][24].…”

Section: Literature Reviewmentioning

confidence: 99%

Optimization of cryo-treated EDM variables using TOPSIS-based TLBO algorithm

et al. 2018

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In order to machine hard and high-strength-to-weight ratio materials, electrical discharge machining (EDM) process is extensively used in aerospace, automobile and other industrial applications. However, high erosion of tool and improper selection of machining variables have emerged as a major obstruction to achieve productivity in this direction. High erosion of tool not only enhances the cost of machining but also increases the machining time by causing interruption during machining. Therefore, proper selection of machining variables and tool material life are the two vital aspects for the tool engineers working in EDM. In view of this, the present work proposes an extensive experimental investigation and optimization of machining variables of cryogenically treated brass tool materials on machining competences of Inconel 718 workpiece. The study primarily highlights the outcome of cryogenically treated soaking duration of tools along with other important process variables, viz. discharge current, open-circuit voltage, pulse-on time, duty factor and flushing pressure, on the performance measures such as electrode wear ratio (EWR), surface roughness and radial over-cut. The study revealed that soaking duration in deep cryo-treatment of the electrode is a significant variable to achieve improved machining characteristics. The performance measures are converted into equivalent single performance measure by calculating the relative closeness coefficient by the techniques for order preferences by similarity to ideal solution (TOPSIS) approach. Finally, a novel teaching-learning-based optimization (TLBO) algorithm has been proposed to find the optimal level of machining variables for the performance measures. The optimal levels of cutting variables obtained through the algorithm are validated through confirmation test, predicting an error of 2.171 percentages between the computational and experimental results. The predicted result suggests that the proposed model can be used to select the ideal process states to achieve productivity for the cryo-treated EDM.

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“…Blind holes were drilled by electrical discharge machining in ceramic composites and hole quality was measured in terms of circularity, perpendicularity, cylindricity [17]. A study in geometric tolerances was done in the EDM of ceramic composites where taper angle, circularity and cylindricity were studied [18]. Grey relational analysis has been successfully employed in some of the non-conventional machining techniques to optimize the process and hence an attempt has been made to apply grey relational analysis for abrasive water jet drilling process.…”

Section: Grey Relational Analysismentioning

confidence: 99%

Optimization of size and form characteristics using multi-objective grey analysis in abrasive water jet drilling of Inconel 617

Nair

Kumanan

2018

J Braz. Soc. Mech. Sci. Eng.

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Inconel 617, a group D category of Superalloys, is the prime material for ultra-supercritical power plant components. Nontraditional machining methods are explored for machining Inconel 617 as the traditional processes are limited. Abrasive water jet machining is very promising in processing hard-to-machine materials and machining of superalloys using abrasive water jet machining needs attention. This paper focuses on establishing hole characteristics in abrasive water jet drilling using multi-objective grey analysis. The form and orientation characteristics of the hole are defined using entry and exit hole overcut, entry and exit hole circularity, taper angle of hole and depth averaged radial overcut apart from drill rate and surface roughness. The process parameters are water jet pressure, standoff distance, and abrasive mass flow rate. Analysis of variance of the individual responses is used to identify the pattern in which each parameter affects the performance of the process. Interaction effects of the various factors have been elaborated using plots. Analysis of means was conducted to obtain the mean effects plot. The results from analysis of variance and analysis of means were compared and good correlation was obtained. The parameter levels for obtaining optimal individual responses were identified and reported. Grey relational analysis combines the attributes of each of the responses into a single grey grade. The grey grade represents the overall hole characteristic of the drilled hole. Analysis of means of the grey grade gives the optimal parameter setting. The adjudged optimal parameters are tested experimentally and reported.

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Optimization of EDM process parameters in machining Si3N4–TiN conductive ceramic composites to improve form and orientation tolerances

Cited by 67 publications

References 22 publications

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Optimization of cryo-treated EDM variables using TOPSIS-based TLBO algorithm

Optimization of size and form characteristics using multi-objective grey analysis in abrasive water jet drilling of Inconel 617

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