Powder-mixed electro-discharge machining performance of Inconel 718: effect of concentration of multi-walled carbon nanotube added to the dielectric media

Jadam, Thrinadh; Sahu, Santosh Kumar; Datta, Saurav; Masanta, Manoj

doi:10.1007/s12046-020-01378-2

Cited by 35 publications

(15 citation statements)

References 28 publications

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“…Finding a solution that will facilitate better MRR while minimizing SR, TWR, and other surface imperfections is very important. To improve machining, one effective method is to add nano-powders to the dielectric fluid in the proper quantity [ 17 , 18 ]. By enhancing spark discharge, the particle’s inclusion in the dielectric fluid lowers the breakdown strength and enhances the igniting mechanism [ 19 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Chaudhari

Shah

Khanna³

et al. 2022

Materials

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In the present study, the effect of alumina (Al2O3) nano-powder was investigated for the electrical discharge machining (EDM) of a Nitinol shape memory alloy (SMA). In addition to the nano-powder concentration, other parameters of pulse-on-time (Ton), pulse-off-time (Toff), and current were selected for the performance measures of the material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR) of Nitinol SMA. The significance of the design variables on all the output measures was analyzed through an analysis of variance (ANOVA). The regression model term has significantly impacted the developed model terms for all the selected measures. In the case of individual variables, Al2O3 powder concentration (PC), Toff, and Ton had significantly impacted MRR, TWR, and SR measures, respectively. The influence of EDM variables were studied through main effect plots. The teaching–learning-based optimization (TLBO) technique was implemented to find an optimal parametric setting for attaining the desired levels of all the performance measures. Pursuant to this, the optimal parametric settings of current at 24 A, PC at 4 g/L, Toff at 10 µs, and Ton of 4 µs have shown optimal input parameters of 43.57 mg/min for MRR, 6.478 mg/min for TWR, and 3.73 µm for SR. These results from the TLBO technique were validated by performing the experiments at the optimal parametric settings of the EDM process. By considering the different user and application requirements, 40 Pareto points with unique solutions were generated. Lastly, scanning electron microscopy (SEM) performed the machined surface analysis. The authors consider this to be very beneficial in the nano-powder-mixed EDM process for appropriate manufacturing operations.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Chaudhari

Shah

Khanna³

et al. 2022

Materials

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“…3f, g, 4g, h and 5g, h. This might be due to continuous event of melting, and resolidification with the accumulation of electron density in dielectric medium results in agglomerated WS 2 particles and stick on the deposited surface. Insufficient heat transfer results in a chunk of deposited particles on the surface at higher WS 2 concentrations [21]. The decrease in LT of 32.12 µm was observed at C p = 8 g/L, P on = 90 µs, and V g = 20 V. This was caused by the Lorenz force, which alters the path of the ions and moves debris particles away from the sparking area [22].…”

Section: Resultsmentioning

confidence: 96%

“…This could be because the molten pool heats up to a temperature above the WS 2 dissociation point. This phenomenon causes sulphur to evaporate and tungsten to remain in the deposited layer [15,20,21].…”

Section: Resultsmentioning

confidence: 99%

Process Optimisation and Tribological Behaviour Studies on Surface Modified Al 6061-T6 Alloy Deposited with WS2 Solid Lubricant Layer Through Electrical Discharge Approach

2021

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In this present work, an attempt has been made to deposit the WS 2 layer on the Al 6061-T6 alloy surface through the electrical discharge deposition (EDD) technique. Specified deposition parameters, namely powder concentration (C p ), pulse-on time (P on ), and gap voltage (V g ) with various levels considered during the EDD process. The experimentation was performed for analysing the results of deposition parameters on material deposition rate (MDR), surface roughness (SR), microhardness (MH), layer thickness (LT), and surface characteristics of the WS 2 layer were examined. The results addressed the various intermetallic compounds formed on the deposited surface. A multi-objective optimisation using Box-Behnken design of response surface methodology was utilised to conduct the deposition process. To predict and optimise the appropriate MDR, SR, MH, and LT, the quadratic model was developed using regression analysis and analysis of variance. Based on the developed model, the interaction effects of deposition parameters on the EDD process were explored. The optimal depositing parameters are determined by maximising the MDR and MH and minimising the SR and LT. The validation test results confirm that experimental data are good in agreement with the predicted results, and hence, the model is feasible to predict the responses adequately. The tribological study was carried out for the optimised condition, and surface characteristics on the worn-out surface were analysed. When compared to the base material, the obtained results show a lower coefficient of friction and specific wear rate.

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“…Apart from this, various methods of flushing in EDM for optimization of machining of AISI 5160 where the generated correlation with Non-dominating sorting genetic algorithm (NSGA) found a more accurate prediction for MRR and SR relative to RSM method [31]. Thermophysical properties of nano particles added in the dielectric significantly affect the machining performance as surface characteristics of machined surface [32]. Coated and uncoated electrode material used in the machining process influence the machine performance [33].…”

Section: Introductionmentioning

confidence: 99%

Machining of nickel-based super alloy inconel 718 using alumina nanofluid in powder mixed electric discharge machining

Patel

Pradhan

2023

Mater. Res. Express

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Inconel 718 is a nickel-based superalloy with exceptional mechanical qualities, including high tensile and impact strength, as well as good oxidation and corrosion resistance. EDM is widely used to cut hard materials of this type by common parameters affecting spark, current, duty cycle etc., whereas MRR, SR can be greatly improved by using sufficient fluid properties of the dielectric. Incorporation of alumina nanoparticles with deionized water may improve machining performance, with no prior research on machining characteristics of Inconel 718 using alumina nanofluid in EDM. The machinability of Inconel 718 via the electrical discharge machining process, as well as the performance of alumina nanofluid as a dielectric medium, have been evaluated using deionized water with a concentration of 0.5%. In this study, based on the effect of various input parameters such as I_p, P_on and G_v on the MRR, TWR and SR, and the RSM has been used to conduct the experiments. A maximum MRR of 0.048 g/min, a TWR of 0.00632 g/min and an SR of 3.271 µm are achieved. Overall, the use of alumina nanofluid can improve machining performance in EDM, due to the reduction of abnormalities such as crack formation and molten metal debris in the machined surface of Inconel 718.

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Powder-mixed electro-discharge machining performance of Inconel 718: effect of concentration of multi-walled carbon nanotube added to the dielectric media

Cited by 35 publications

References 28 publications

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Experimental Investigations and Effect of Nano-Powder-Mixed EDM Variables on Performance Measures of Nitinol SMA

Process Optimisation and Tribological Behaviour Studies on Surface Modified Al 6061-T6 Alloy Deposited with WS2 Solid Lubricant Layer Through Electrical Discharge Approach

Machining of nickel-based super alloy inconel 718 using alumina nanofluid in powder mixed electric discharge machining

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