Performance evaluation of graphite and titanium oxide powder mixed dielectric for electric discharge machining of Ti–6Al–4V

Alam, Shah; Amin, Akm Nurul; Hossain, Md. Ibrahim; Huq, Maliha; Tamim, Shaqauit Hossain

doi:10.1007/s42452-021-04450-6

Cited by 17 publications

(6 citation statements)

References 28 publications

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“…The modification on a PM-EDMed surface can be evidenced in the form of a noticeably thick recast layer exhibiting upgraded surface properties such as improved surface integrity, micro-cracks, corrosion resistance, wear resistance, and biocompatibility [ 214 , 215 ]. In the case of PM-EDM of Ti and Ti alloys, B 4 C [ 216 ], surfactant, graphite, TiO 2 [ 217 , 218 ], SiC, Al 2 O 3 [ 219 – 222 ], Si [ 223 ], and carbon nanotubes (CNTs) [ 224 ] powder particles were primarily used. For instance, with variation in the powder characteristics (particle sizes and concentrations) of SiC and Al 2 O 3 powders and dielectric mediums (such as EDM oil, deionized water, and tap water), considerable changes in the surface roughness (SR), recast layer thickness (RLT), material subtraction/removal rate (MRR), and tool wear rate (TWR) were witnessed [ 225 – 227 ].…”

Section: Surface Modification Of Metallic Implant Biomaterialsmentioning

confidence: 99%

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Davis

Singh

Jackson

et al. 2022

Int J Adv Manuf Technol

145

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There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers’ attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.

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Section: Surface Modification Of Metallic Implant Biomaterialsmentioning

confidence: 99%

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Davis

Singh

Jackson

et al. 2022

Int J Adv Manuf Technol

145

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“…Specimens machined with Gr electrode exhibit average Ra value of 2.54 μm, and it was increased to 2.65 μm and 2.87 μm when machined with Br and Cu electrode, respectively. Because of the Cu electrode's superior thermal conductivity, very high intensity heat was generated, causing deeper craters and cracks to develop on the machined face, resulting in higher Ra value than a Br-machined specimen [49]. When machined with Gr electrode, as the majority of heat was passed to the tool material, the work piece was subjected to low spark, resulting in improved surface quality.…”

Section: Influence Of Various Process Parameters On the R A Of Az91mentioning

confidence: 99%

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Prakash¹,

Ranjith²,

Mohan

et al. 2022

Advances in Materials Science and Engineering

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In this work, an attempt was made to machine the AZ91/5B4C/5Gr hybrid composites in a castor oil electric discharge medium with an objective of attaining green environment. The hybrid composites were produced using stir casting technique in a protective environment. Experiments were conducted by varying dielectric fluid (castor oil and hydrocarbon oil), tool materials (copper, graphite, and brass), polarity, current, pulse-on time, and gap distance in Al2O3 mixed dielectric medium. L36 Taguchi approach was adopted for the design of experiments, and machining performance was accessed in terms of material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra). Because of castor oil’s high thermal conductivity, high kinematic viscosity, and lower dielectric strength, the specimen exhibits 5% higher MRR than EDM oil. When the electrodes were connected to the negative polarity, the Ra was 1.72 μm and 3.66 μm at positive polarity; however, at negative polarity, the TWR was higher than the MRR. The high density and specific heat of castor oil facilitate flushing and uniform heat distribution; as a result, the composite had a Ra of 2.52 μm compared to 2.86 μm when machined with conventional EDM oil. Surface topography showed the specimen machined with hydrocarbon dielectric medium proffers black spots, which were eliminated in castor dielectric medium. Best parametric combination was selected by the Relative Index Method optimization technique.

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“…The minimal magnitude of TWR is observed with the positive polarity using a copper electrode in a graphene-based slurry. Alam et al [1] investigated the performance of power mixed EDM in the machining of Ti-6Al-4V in terms of MRR and TWR. The study adopted surface response methodology to investigate the influence of process parameters including peak current, powder type, and powder concentration on MRR, TWR.…”

Section: References Process Used Workpiece Materials Tool Materialsmentioning

confidence: 99%

“…These characteristics are very important components performance, durability, and reliability. Many research studies were published to investigate the use of the EDM technique in surface treatment, and found that the surface was improved [1,27,47].…”

Section: Surface Integritymentioning

confidence: 99%

“…

New challenges in the manufacturing sector, have lead manufacturers to development of reliable and high-quality products as per requirements. Nowadays, to enhance productivity and maintain the surface quality of complex parts, researchers have focused on high-speed machining technologies that involve electron beam machining (EBM), computer numerical control (CNC) machining, chemical machining, laser beam machining (LBM), and electric discharge machining (EDM) [1]. Chemical machining creates a hazardous environment while EBM and LBM need significant investments relative to EDM [2].

…”

mentioning

confidence: 99%

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Performance evaluation of electric discharge machining of titanium alloy-a review

2022

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Titanium alloy has a high specific resistance, excellent machining performance is non-corrosive, and the capability to withstand greater temperatures while maintaining outstanding mechanical properties. This alloy is, therefore, the right choice for aerospace, maritime, biomedical, and industrial applications. But machinability of titanium alloy is challenging as a result of its poor thermal conductivity, highly chemically reactive, and low elastic modulus hence it is treated as a difficult-to-cut material. Fast tool wear is observed during the machining of titanium alloy in conventional machining methods. Therefore, unconventional processing methods are used for the treatment of titanium alloy. Electric discharge machining (EDM) is one of these unconventional machining processes which are used for cutting with high precision, having a high degree of machinability, and getting a better surface finish. It is considered the best choice for machining titanium alloy. In the EDM process, different techniques are used to understand the effects of process parameters such as polarity, peak current, electrode type, pulse on time, and gap voltage on material removal rate, tool wear rate, surface roughness, and wear ratio. This paper critically investigates different types of EDM processes, experimental setups used for machining of titanium alloy, the effect of different tool electrodes and dielectric media on machining parameters, machined surface characteristics, and metal removal rate and tool wear rate.

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Performance evaluation of graphite and titanium oxide powder mixed dielectric for electric discharge machining of Ti–6Al–4V

Cited by 17 publications

References 28 publications

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Electric Discharge Machining of AZ91 Magnesium Hybrid Composites under Different Dielectric Mediums

Performance evaluation of electric discharge machining of titanium alloy-a review

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