Abstract:In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop … Show more
“…Experiments 1 and 16 utilize non-composite tools made of copper, with a 50% duty cycle and a duty ratio of 0.5. In both cases, no arcing observed [48]. This demonstrates that non-composite tools can handle a higher duty ratio without experiencing arcing.…”
In this research, an attempt was made to reinforce aluminium with graphite particles and use it as a tool material with the objective of combining the properties of aluminium and graphite. The micrograph confirms that the graphite particles were uniformly distributed over the aluminium matrix, density reduces and thermal conductivity increases with the addition of graphite particles. Material Removal Rate (MRR) peaks at 12A current before declining due to plasma channel expansion, an optimal Ton of 8µs ws observed, with 4µs Toff yielding higher MRR. Copper electrodes excel due to thermal conductivity, while 5% graphite in aluminum boosts MRR to 31.89mm³/min, additional graphite decreases MRR. TWR rises with shorter Toff until 6µs, then decreases. Gap control impacts TWR, with lower spark gaps causing higher TWR due to intense material removal, and higher gaps leading to increased TWR due to incomplete flushing. Copper electrodes have the lowest TWR due to their high melting temperature. The addition of graphite in aluminum reduces TWR at low currents but is less effective at higher currents. Surface roughness (Ra) decreases with higher current, reaching a minimum of 7.02µm at 12A. Optimal Ton is 8µs (7.56µm), while shorter Toff at 4µs and a 3mm gap yield the best Ra of 7.36µm with A4 composite tool. Copper electrodes result in higher Ra at higher currents, while graphite in aluminum improves surface quality, especially at 5% content. Arcing, an undesirable electrical discharge phenomenon in EDM, adversely affects machining. Experiments revealed a strong correlation between high duty cycles, duty ratios, and arcing propensity, with composite tools being more susceptible due to their variable conductivity. In contrast, non-composite tools, exemplified by copper, withstand higher duty ratios without arcing.
“…Experiments 1 and 16 utilize non-composite tools made of copper, with a 50% duty cycle and a duty ratio of 0.5. In both cases, no arcing observed [48]. This demonstrates that non-composite tools can handle a higher duty ratio without experiencing arcing.…”
In this research, an attempt was made to reinforce aluminium with graphite particles and use it as a tool material with the objective of combining the properties of aluminium and graphite. The micrograph confirms that the graphite particles were uniformly distributed over the aluminium matrix, density reduces and thermal conductivity increases with the addition of graphite particles. Material Removal Rate (MRR) peaks at 12A current before declining due to plasma channel expansion, an optimal Ton of 8µs ws observed, with 4µs Toff yielding higher MRR. Copper electrodes excel due to thermal conductivity, while 5% graphite in aluminum boosts MRR to 31.89mm³/min, additional graphite decreases MRR. TWR rises with shorter Toff until 6µs, then decreases. Gap control impacts TWR, with lower spark gaps causing higher TWR due to intense material removal, and higher gaps leading to increased TWR due to incomplete flushing. Copper electrodes have the lowest TWR due to their high melting temperature. The addition of graphite in aluminum reduces TWR at low currents but is less effective at higher currents. Surface roughness (Ra) decreases with higher current, reaching a minimum of 7.02µm at 12A. Optimal Ton is 8µs (7.56µm), while shorter Toff at 4µs and a 3mm gap yield the best Ra of 7.36µm with A4 composite tool. Copper electrodes result in higher Ra at higher currents, while graphite in aluminum improves surface quality, especially at 5% content. Arcing, an undesirable electrical discharge phenomenon in EDM, adversely affects machining. Experiments revealed a strong correlation between high duty cycles, duty ratios, and arcing propensity, with composite tools being more susceptible due to their variable conductivity. In contrast, non-composite tools, exemplified by copper, withstand higher duty ratios without arcing.
“…Given that air goes from a high-pressure zone to a low-pressure zone, this task might be finished really rapidly. Appropriately placed airfoils allow gases to flow and expand through the turbine's blades and vanes without interruption [22][23][24].…”
Turbine blades are the separate components that make up the turbine section of a steam or gas turbine. The blades must transform the high-temperature, high-pressure gas that the combustor produces into energy. In gas turbines, the turbine blades are usually the limiting element. As gas temperatures rise, the amount of heat that reaches the blades will also grow dramatically, leading to their thermal failure. Because gas turbine blades must function in extremely high temperatures, cooling is crucial. After FEA simulation was conducted and radial perforations of 6, 9, and 12 were constructed to allow high-velocity cooling air to pass through, the cooling of the gas turbine blades was improved.
“…These reasons led us to perform experimental research, the goal of which was to achieve significant progress in optimizing the quality of the machined surface while maintaining high productivity of the electrical discharge process. At the same time, we would like to contribute to the database of already existing knowledge through clear formulations of particular laws in relation to the processes that take place directly on the machined surface during the electrical discharge [ 58 , 59 , 60 , 61 , 62 , 63 , 64 , 65 ].…”
When machining high-speed steels (HSS) with micro-wire electrical discharge machining (micro-WEDM), high surface quality is achieved as standard. The value of the roughness parameter Ra is less than 0.2 μm. However, the problem is the performance of the electroerosion process (MRR), which is low. This problem is related to the mechanical and physical properties of the HSS in combination with the setting of the main technological parameters (MTP). The proposed solution to eliminate this problem relies on the selection of proper procedures for the determination of optimization criteria in relation to Ra and MTP, with the inclusion of properties of the machined material. The solution consisted in the identification of four significant physical (ρ, κ) and mechanical (Rm, HRC) indicators of HSS properties, on the basis of which a suitable combination of the process output parameters Ra and MRR can be determined through established mathematical regression models using simulation and optimization. In the next step, the proper values of the MTP output process parameter settings, which correspond to the optimized output parameters Ra and MRR during machining of HSS by micro-WEDM technology, were then obtained by the same approach.
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