Parametric Optimization and Influence of Near-Dry WEDM Variables on Nitinol Shape Memory Alloy

Chaudhari, Rakesh; Kevalramani, Aniket; Vora, Jay; Khanna, Sakshum; Patel, Vivek; Pimenov, Danil Yurievich; Giasin, Khaled

doi:10.3390/mi13071026

Cited by 16 publications

(8 citation statements)

References 90 publications

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“…Many researchers studied optimizing the process parameter in WEDM of SMA to enhance the process performance [33][34][35]. The surface roughness and MRR are the important response factors for the quality and overall productivity in WEDM of NiTi shape memory alloy [36][37][38].…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on WEDM parameters of Ni-rich nitinol plate

et al. 2023

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Wire Electro discharge machining (WEDM) process is extensively employed to fabricate miniaturized products. Ni-Ti shape memory alloy(Nitinol) finds its primary application in many significant engineering areas and biomedical fields because of its inherent properties, like shape recovery, superior biocompatibility, and elasticity. The current research investigates the shape recoverability characteristics of WEDM machined nitinol. WEDM Experiments conducted through DOE with significant input factors like the current(I), pulse on time (Ton), and Wire Feed (f). The responses recorded are material removal rate (MRR), wire wear rate(WWR), percentage of shape recovery(R), kerf width(w), and surface roughness(Ra). The mathematical model developed was to predict the response for corresponding input factors, and the variances of the model are analyzed. Significant contributors are identified from ANOVA, and surface plots are drawn to show the interaction effects. The morphological behavior of the surface was analyzed by FESEM and compositional analysis by EDAX. Surface topography is analyzed in surface roughness, and microhardness was measured to understand the process relevant to shape recoverability better. The results reveal that current and pulse on time affect the microhardness and surface roughness, altering the machined alloy’s shape recoverability.

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Section: Introductionmentioning

confidence: 99%

Experimental investigation on WEDM parameters of Ni-rich nitinol plate

et al. 2023

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“…Powder mixed near-dry EDM outperformed conventional EDM in terms of tool wear, surface roughness, material removal rate, residual stress, and micro hardness [23]. Very recently, various dry and near-dry EDM experimental research studies were performed to improve the surface and machining speed using different gases, and gas-mist dielectric fluids [24][25][26].…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Janardhana

Anushkannan²,

Dinakaran

et al. 2023

Eng. Res. Express

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In this research, the environment-friendly dry electrical discharge machining (EDM) process is investigated to improve the microhardness, surface finish, and white layer thickness of the machined surfaces using graphite-argon gas as a dielectric medium. The graphite powder, mixed with compressed argon gas, has been used to replace the existing dielectric medium in the EDM process. Gas pressure, discharge current, pulse width, and gap voltage were working as input parameters to reduce surface roughness and enhance the microhardness and white layer thickness. The Taguchi L16 orthogonal array is applied to the design and analysis of the experimental results. The minimum surface roughness (2.23 µm) of the HN31 steel has been attained by increasing the gas pressure up to 1.0 MPa and the minimum values of pulse width (40 µs), gap voltage (40 V), and discharge current (6 A). The maximum microhardness (501.04 HV) has been obtained at 1.2 MPa of gas pressure, 120 µs of pulse width, 60 V of gap voltage, and 18 A of discharge current. The maximum white layer thickness (16.24 µm) is achieved by the maximum values of gas pressure (1.2 MPa), pulse width (160 µs), gap voltage (70 V) and discharge current (18 A). The SEM analysis had been done to reveal the white recast layer thickness and surface roughness of the machined surfaces of the dry EDM process. The SR is increased by the recast layer, pores, and microcracks on the machined surfaces. Finally, the multi-criteria optimization technique: Weight Product Method (WPM) is applied to predict optimum process parameter settings: GP: 1.2 MPa, PW: 120 µs, GV: 50 V, and DC: 18 A to meet the best machining performances (MH=493.32 HV, WLT= 14.28 µm, and SR= 3.82 µm). The validation tests were done to confirm the predicted results obtained by both the Taguchi and WSM methods.

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“…The results of confirmation runs have revealed the successful performance of the NDWEDM process. Chaudhari et al [22] analyzed the effect of the NDWEDM approach to lessen the environmental impact of wet WEDM. A parametric optimization was conducted with input factors of current, Ton, and Toff.…”

Section: Introductionmentioning

confidence: 99%

Effect of Near-Dry WEDM Process Variables through Taguchi-Based-GRA Approach on Performance Measures of Nitinol

Vora

Shah

Khanna³

et al. 2022

JMMP

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The machining of Nitinol shape memory alloys (SMA) through conventional machining techniques imposes several challenges due to the alloys’ comprehensive mechanical qualities. Wire electrical discharge machining (WEDM) process is a non-conventional machining technique that is suitable mainly for producing complex shape geometries with excellent surface features for difficult-to-cut materials. The current study attempted the use of a near-dry WEDM process for Nitinol SMA with the consideration of multiple response variables. The studied literature and machine capabilities have identified input factors of pulse-on-time (Ton), pulse-off-time (Toff), and current and output factors of MRR, SR, and RLT. Through the Taguchi approach, a total of nine experimental trials were designed to analyze the performance of the process. The statistical significance of input factors on the performance measures was studied with the help of ANOVA techniques. Statistical analysis for all the output measures has shown that the generated regression terms had a significant influence. For single output measures, the current was found to have a substantial effect on both MRR and SR, while Toff was the most significant contributor in the case of RLT. The obtained results of residual plots for all performance measures implied good ANOVA results. The effect of near-dry WEDM variables was studied on output measures through main effect plots. Grey relational analysis (GRA) has been employed to attain optimal parametric settings of multiple performance measures. GRA technique for the optimal parametric settings of simultaneous performance measures of MRR, SR, and RLT was found to have a Ton of 30 µs, Toff of 24 µs, and current of 4 A. Validation trials were conducted to check the adequacy of the GRA technique. The minor acceptable deviation was recorded among the anticipated and recorded values. This clearly reveals the acceptability of the integrated approach of the Taguchi–Grey method. The surface morphology for the near-dry and wet-WEDM has also been investigated through scanning electron microscopy (SEM). The author considers that the present study will be beneficial for users working in WEDM and near-dry WEDM processes for hard machining materials.

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Parametric Optimization and Influence of Near-Dry WEDM Variables on Nitinol Shape Memory Alloy

Cited by 16 publications

References 90 publications

Experimental investigation on WEDM parameters of Ni-rich nitinol plate

Experimental investigation on WEDM parameters of Ni-rich nitinol plate

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Effect of Near-Dry WEDM Process Variables through Taguchi-Based-GRA Approach on Performance Measures of Nitinol

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