Study of surface crack density and microhardness of Aluminium 6061 alloy machined by EDM with mixed powder and assisted magnetic field

Rouniyar, Arun Kumar; Shandilya, Pragya

doi:10.1177/25165984211016445

Cited by 13 publications

(3 citation statements)

References 39 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The experiment yielded an average MRR of 40 µg/min, confirming the Maglev EDM’s capability for micro-hole production on conductive materials. Rouniyar et al 17 introduced MFA powder mixed EDM as an innovative hybrid technique to enhance machining performance by incorporating powder into the dielectric medium and applying an MF. Aluminium 6061 alloy was processed using this setup, with a focus on individual process parameter effects on surface crack density (SCD) and microhardness (MH).…”

Section: Introductionmentioning

confidence: 99%

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

Varshney,

Singh

2024

Journal of Micromanufacturing

View full text Add to dashboard Cite

This comparative study investigates the effect of various magnetic field (MF) intensities on the precision machining of cylindrical workpiece of EN24 Steel alloy in the electrical discharge turning configuration. EN24 steel is a high-strength alloy commonly employed in aerospace, automotive, and general engineering applications. The objective of this research is to evaluate the impact of MF intensity on the material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness ( Ra). The rotational speed of the workpiece, peak current, and pulse-on time were kept constant machining parameters throughout the experiments. The experimental results reveal that increasing MF intensity enhances MRR, OC, and surface finish. However, it is observed that higher MF intensities lead to an elevate TWR which was a negative effect on machining performance. SEM analysis was conducted on the machined surface, revealing that higher magnetic intensity resulted in the formation of a reduced recast layer and remelted debris. The findings were further supported by energy-dispersive spectrum results, which indicated a lower presence of oxide and carbide formations on the machined surface when subjected to higher MF intensity.

show abstract

Section: Introductionmentioning

confidence: 99%

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

Varshney,

Singh

2024

Journal of Micromanufacturing

View full text Add to dashboard Cite

show abstract

“…However, the work is limited to finish machining regime alone [37]. Authors tried to explore the significance of adding Cr [38], Al 2 O 3 [39], nanoalumina and SiC [40] powders into the liquid dielectric during EDM process. Authors reported that lessened surface cracks were noticed in PMEDMed surface compared to that produced by conventional EDM [41].…”

Section: Introductionmentioning

confidence: 99%

Exploring the influence of powder particles in dielectric liquid of EDM: pulse train, discharge energy, material removal rate and surface topography

Rajesh,

Giridharan

2023

Phys. Scr.

View full text Add to dashboard Cite

A comparative study on the effect of adding molybdenum di-sulphide (MoS2) powders of diameters 40 m, 90 nm size into an ultrasonic vibration induced dielectric liquid of electrical discharge machining (EDM) process is attempted. Discharge duration, peak current, gap voltage are selected as input variables and their impact is assessed using pulse train, discharge energy, material removal rate (MRR) and surface integrity which are considered as outcome measure. The outcome measures of powder mixed dielectric (PMD) are compared with that of pure dielectric. Through pulse trains, a new phenomenon of partial discharge is identified. The incidence of partial discharge are assessed using scanning electron microscope (SEM) images. By varying the discharge duration, peak current and gap voltage, the discharge energy reduces in contrast to pure dielectric by 4%, 21.01%, 8.35% respectively for 40 m diameter PMD and 10%, 27.29%, 17.99% respectively for 90 nm diameter PMD. The increase of peak current and gap voltage magnitudes cause the discharge energy to rise whereas discharge energy drops with growing magnitudes of discharge duration. Compared to the pure dielectric, the PMD produced enhanced MRR for similar discharge energy levels. The peak current has shown greater influence on MRR than discharge duration and gap voltage. In comparison with pure dielectric, the machining performance has improved by 21% for 40 µm diameter PMD, whereas 84.21 % for 90 nm diameter PMD. At higher discharge parameters, better surface topography is produced in PMD than pure dielectric.

show abstract

“…AK Rouniyar, P Shandilya [17] studied the micro hardness of EDM machined AA6068. The results concluded that microhardness is increased for machined sample than the parent material which is owing to the carbide and oxide layer formation on the surface, quenching effect.…”

Section: Introductionmentioning

confidence: 99%

Investigations on the effect of dielectric medium and WEDM parameters on surface characteristics of Al 7068 (ordnance aluminium) alloy

SHARMILA¹,

Selvakumar²,

S³

2022

Surf. Topogr.: Metrol. Prop.

View full text Add to dashboard Cite

The current experimental work focuses on determining the optimum machining parameter combination for machining AA7068 in wire electrical discharge machining (WEDM). WEDM is a promising advanced machining technology, capable of processing complex-shaped components, machining hard/heat treated materials, and cutting conductive ceramics that are complicated to machine using traditional methods. Taguchi’s L18 orthogonal array is adopted to conduct the experiments by considering dielectric medium, pulse on time, pulse off time, peak current, gap voltage, and wire feed as input factors. The output responses like surface roughness, material removal rate, micro hardness, recast layer, surface morphology of the machined surfaces and wire tool were considered for study. The ANOVA method was used to analyse the impact of individual processing parameters on material removal rate and surface roughness. Micro hardness of the cut surface was studied using Vicker’s method. Besides, scanning electron microscopy (SEM) and Energy Dispersive X-Ray analysis are conducted to examine the surface characteristics and elemental composition of the machined working piece at various cutting parameters (EDX). TOPSIS method is chosen to identify the optimal parametric conditions. From the results, the optimum condition achieves surface roughness (3.684 µm) and material removal rate (5.106 mm3/min) respectively.

show abstract

Study of surface crack density and microhardness of Aluminium 6061 alloy machined by EDM with mixed powder and assisted magnetic field

Cited by 13 publications

References 39 publications

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

Exploring the influence of powder particles in dielectric liquid of EDM: pulse train, discharge energy, material removal rate and surface topography

Investigations on the effect of dielectric medium and WEDM parameters on surface characteristics of Al 7068 (ordnance aluminium) alloy

Contact Info

Product

Resources

About