Optimization of micro-EDM drilling of inconel 718 superalloy

Ay, Mustafa; Çaydaş, Ulaş; Hasçalik, Ahmet

doi:10.1007/s00170-012-4385-8

Cited by 156 publications

(51 citation statements)

References 20 publications

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“…This method is used to analyze the multi-performances in experimental studies and has some advantages than statistical [22]. Fig.…”

Section: B Grey Relational Analysis-mentioning

confidence: 99%

Optimization of Electro Discharge Machining of Superalloys and Composites: A Review

2015

International Conference on Advancements and Recent Innovations in Mechanical, Production and Industrial Engineering

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Abstract-Electro discharge machining (EDM) processis a well-established advanced machining process for producing complex geometry with close tolerances in these materials that are extremely difficult-to-machine by conventional machining processes. EDM process offers a better alternative or sometimes the only alternative for generating accurate three dimensional complex shapes of macro, micro and nano features in difficult-tomachine materials among other advanced machining processes. The success of the EDM process depends upon the selection of appropriate process parameters. The selection of preferred process parameters plays a significant role to ensure quality of product and to reduce the machining cost in computer controlled machining process. Hence, Optimization methods applied for machining process are necessary for continuous improvement of the machining process. The objective of this paper is to offer comprehensive knowledge concerning the optimization of electro discharge machining of superalloys and composites materials.

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“…This method is used to analyze the multi-performances in experimental studies and has some advantages than statistical [22]. Fig.…”

Section: B Grey Relational Analysis-mentioning

confidence: 99%

Optimization of Electro Discharge Machining of Superalloys and Composites: A Review

2015

International Conference on Advancements and Recent Innovations in Mechanical, Production and Industrial Engineering

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“…With the further research and application of the micro-EDM technology, people are more and more realize that the current research on the basic theory of the micro-EDM has become a huge resistance to the further development of the technology [14] [15]. The theoretical basis of EDM is to predict the machining efficiency, the loss of tool electrodes, and machining surface quality [16] [17]. However, owing to the randomness of spark discharge and the lack of research methods, it is difficult to predict the process accurately.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Micro Structures by Ultrashort Voltage Pulse Electrical Discharge Machining

Wang¹,

He²,

Xiao³

2018

JMMCE

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The machining of small holes and array holes has been a difficult problem in machining field. Tiny hole is widely used in mechanical field, for instance, fuel injection nozzles, spinneret holes for synthetic fibers and wire drawing dies. This paper investigated the application of EDM (electrical discharge machining) to the fabrication of micro structures. There are obvious limitations in the process of micro-electrical discharge machining, such as electrode wear, unstable discharge condition and low machining efficiency. The effects of EDM parameters were investigated, such as voltage, pulse frequency, and frequency of ultrasonic vibration applied to electrode. Micro holes were machined with Pt electrode made by focused-ion-beam chemical vapor deposition (FIB-CVD) and Cu electrode made by wire-electrode cutting. The comparison experiments between EDM and ECM (electrochemical machining) indicated that the processing of ECM has serious stray current corrosion and poor machining precision. Moreover, the workpiece vibration was firstly proposed to be utilized in the micro-electrical discharge machining. It can be concluded that maximum machine could be obtained under the amplitude ratio of 76%, which was an appropriate parameter.

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“…While machining Inconel, the significant challenges are that they have low thermal conductivity which increases thermal effects during machining; they often exhibit strong work hardening behaviour, high adhesion characteristic onto the tool face altering cutting process parameters completely. In addition, they may contain hard abrasive particles and carbides that create excessive tool wear, and hence, the surface integrity of the end products appears disappointing [1]- [4]. Compared to conventional cutting, electrical discharge machining (EDM) seems a competent alternative to machine those super alloys.…”

Section: Introductionmentioning

confidence: 99%

Machining Performance Optimization for Electro Discharge Machining of Inconel 625: A Case Experimental Study

Rahul¹,

Upadhyay²,

Datta³

et al. 2017

IJMMM

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Abstract-An experimental investigation on assessing machining performance during Electro-Discharge Machining (EDM) of Inconel 625 has been attempted herein. Based on 5-factor-4-level L 16 orthogonal array, experiments have been carried out by varying gap voltage, peak current, pulse-on time, duty factor and flushing pressure (each varied into four discrete levels) to examine machining performance characteristics like electrode wear ratio, radial overcut, roughness average, and surface crack density of EDMed end product obtained by utilizing different parameters settings as per design of experiment. An integrated optimization route combining satisfaction function approach and Taguchi's philosophy has been proposed for simultaneous optimization of aforementioned multiple performance indices. Predicted optimal parameters setting has been verified by confirmatory tests. In addition to that, analysis of SEM micrographs has been carried out to investigate surface irregularities for EDMed Inconel 625 end products.Index Terms-Electro-discharge machining, inconel 625, satisfaction function approach, Taguchi's philosophy. I. INTRODUCTIONInconel alloys are Nickel-Chromium based high temperature super alloys popular for applications in aerospace, marine, and nuclear power generation, chemical, petrochemical and process industries. While machining Inconel, the significant challenges are that they have low thermal conductivity which increases thermal effects during machining; they often exhibit strong work hardening behaviour, high adhesion characteristic onto the tool face altering cutting process parameters completely. In addition, they may contain hard abrasive particles and carbides that create excessive tool wear, and hence, the surface integrity of the end products appears disappointing [1]- [4]. Compared to conventional cutting, electrical discharge machining (EDM) seems a competent alternative to machine those super alloys. It is an indeed necessity to determine the most favorable process environment (parameters setting) to optimize multiple process-performance yields, simultaneously. has been used as a tool electrode (Fig. 2). The experiments have been carried out on die sinking EDM (Make: Electronica ElektraPlusPS 50ZNC, India) setup. Commercially available grade EDM oil with specific gravity of 0.763 has been used as dielectric fluid. Polarity has been kept positive (i.e., workpiece positive). Experiments have been carried out using five controllable process parameters (gap voltage, peak current, pulse-on time, duty factor, and flushing pressure) each varied at four different levels ( Table I) International Journal of Materials, Mechanics and Manufacturing, Vol. 5, No. 4, November 2017 228 doi: 10.18178/ijmmm.2017.5.4.324 Experimental data (Table II) (Fig. 5) Predicted S/N ratio of (d T ) at optimal setting has been determined as: 6.09197 dB. In all cases (except run no. 10), predicted S/N ratio at optimal setting has been found maximum as compared to the S/N ratio values as computed for all experimental run...

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Optimization of micro-EDM drilling of inconel 718 superalloy

Cited by 156 publications

References 20 publications

Optimization of Electro Discharge Machining of Superalloys and Composites: A Review

Optimization of Electro Discharge Machining of Superalloys and Composites: A Review

Fabrication of Micro Structures by Ultrashort Voltage Pulse Electrical Discharge Machining

Machining Performance Optimization for Electro Discharge Machining of Inconel 625: A Case Experimental Study

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