μED milling of Ti-6Al-4V using cryogenic-treated Wc tool and nano-graphene powder-mixed dielectricat different discharge energy regimes

Pillai, Karthik; Hariharan, P.; Jafferson, J.M.

doi:10.1007/s00170-019-03327-8

Cited by 18 publications

(8 citation statements)

References 14 publications

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“…Under medium DER, the combination of sufficient energy for powerful discharges and a short pulse off time improves material removal. Similar results are reported by Pillai et al 4 .…”

Section: Analysis Of Mrrsupporting

confidence: 92%

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Experimental Investigations on µED Milling of Inconel 718 with Nano SiC Abrasive Mixed Dielectric

Elumalai¹,

Gowri

Hariharan

et al. 2022

Mat. Res.

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“…Under medium DER, the combination of sufficient energy for powerful discharges and a short pulse off time improves material removal. Similar results are reported by Pillai et al 4 .…”

Section: Analysis Of Mrrsupporting

confidence: 92%

“…Pillai et al 4 analyzed the effect of nano-Graphene powder on micro EDM of Ti-6Al-4V alloy with a cryogenic-treated tungsten carbide tool. The results indicate substantial improvements in MRR, TWR, and surface finish due to the cryogenic treatment of the tool and due to the addition of nano-Graphene powder into the dielectric.…”

Section: Powder Mixed Edmmentioning

confidence: 99%

Experimental Investigations on µED Milling of Inconel 718 with Nano SiC Abrasive Mixed Dielectric

Elumalai¹,

Gowri

Hariharan

et al. 2022

Mat. Res.

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“…When the discharge energy increases, the gap between the tool and workpiece gets enlarged, resulting in excellent removal of debris particles from the machining region, thereby decrease in unwanted discharges. This is responsible for the minimium electrode wear [2]. It is also observed from the (figure 4) that the EWR reaches a maximum at medium discharge energy region due to a smaller gap between the consecutive electrical sparks resulting in excessive heating of electrode material leading to rapid erosion of electrode material.…”

Section: Analysis Of Ewrmentioning

confidence: 86%

“…Therefore, an unconventional cutting process, namely the Micro ED milling process, can be the good option for machining of alloys (Ti-6Al-4V) without any constraint because a series of discharged sparks is used to vaporize the work material. In the process, the gap between the electrodes ( workpiece and tool) is small, leads to poor surface texture and low MRR [1,2]. Inorder to improve the flushing rate of debris and machining efficiency, the researchers are utilized various strategies viz.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on the recast layer and performance indicators during nano powder mixed μED miling of Ti-6Al-4V

K¹,

Hariharan²

2021

Surf. Topogr.: Metrol. Prop.

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Micro ED milling is an excellent microfabrication technique for machining of complex micro shapes and microstructures. It has the potential to machine any electrically conductive material irrespective of its mechanical characteristics. In this work, the effect of different nanopowders, namely graphite (Gr) and carbon nano tubes (CNT) powder and their concentration on response indicators while machining of Ti-6Al-4V under different discharge energy regions is investigated. The surface texture of the milled surface with plain dielectric and nanopowder mixed dielectrics have also analyzed. The highest MRR was achieved with CNT powder as compared to graphite powder due to its high electrical conductivity. The mixing of nanopowder particles in dielectric resulted in a smoother surface than plain dielectric due to the uniform distribution of heat energy over the machining region. It was found the thickness of the recast layer is reduced due to the addition of nanopowders in the dielectric fluid. The maximium recast layer thickness (4.14 μm) is observed with the plain dielectric at high discharge energy. The thickness of the recast layer seems to be minimium when higher-order powder concentration is used. Nanopowder mixed dielectrics offered a better material removal rate than plain dielectric at the cost of overcutting. Material migration is lesser in the case of nanopowder mixed dielectrics due to an increase in number of discharges per second. The material migration is reduced by 54% and 31%, due to the addition of CNT and Gr powders in dielectric respectively. Tool life gets improved with nanopowders mixed dielectric due to the reduction of unwanted discharges and embdement of powder particles on tool material. List of Abbreviations CNT Carbon nano tubes Gr Graphite μEDM Micro Electrical discharge Machining μm Micro Meter nm Nanometer RPM Rotation per minute g/l Grams per liter μJ Micro joules MRR Material removal rate EWR Electrode wear rate WC Tungsten carbide D.E.R Discharge energy region SEM Scanning Electron Microscope RECEIVED

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“…103,104 Another significant phenomenon related to powder concentration in the dielectric is electron hijacking which contributes to a rougher surface and reduction in MRR when powder concentration is increased above a certain optimum value. 105 Kumar et al 106 studied the effect of Graphene nano-powder in PMEDM, the study revealed improvement in surface finish required in the optics and semiconductor industries. In a comparative study between water-based dielectric and hydrocarbon-based dielectric medium, it was observed that SiC particles, in the water-based dielectric, gained high kinetic energy which enabled them to penetrate the workpiece material.…”

Section: Meticulous and Lucid Study Of Powder Mixed Edmmentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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μED milling of Ti-6Al-4V using cryogenic-treated Wc tool and nano-graphene powder-mixed dielectricat different discharge energy regimes

Cited by 18 publications

References 14 publications

Experimental Investigations on µED Milling of Inconel 718 with Nano SiC Abrasive Mixed Dielectric

Experimental Investigations on µED Milling of Inconel 718 with Nano SiC Abrasive Mixed Dielectric

Experimental investigation on the recast layer and performance indicators during nano powder mixed μED miling of Ti-6Al-4V

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

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