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Abstract

The development of industry is determined by the use of modern materials in the production of parts and equipment. In recent years, there has been a significant increase in the use of nickel-based superalloys in the aerospace, energy and space industries. Due to their properties, these alloys belong to the group of materials hard-to-machine with conventional methods. One of the non-conventional manufacturing technologies that allow the machining of geometrically complex parts from nickel-based superalloys is electrical discharge machining. The article presents the results of experimental investigations of the impact of EDM parameters on the surfaces roughness and the material removal rate. Based on the results of empirical research, mathematical models of the EDM process were developed, which allow for the selection of the most favourable processing parameters for the expected values of the surface roughness Sa and the material removal rate.

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Authors and Affiliations

Rafał Świercz
1
Dorota Oniszczuk-Świercz
1
Lucjan Dąbrowski
1

  1. Warsaw University of Technology, Institute of Manufacturing Technology, Warsaw, Poland.
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Abstract

In this paper, a study was carried out to investigate the surface roughness and material removal rate of low carbon NiTi shape memory alloy (SMA) machined by Wire Electro Spark Erosion (WESE) technique. Experiments are designed considering three parameters viz, spark ON time (SON), spark OFF time (SOFF), and voltage (V) at three levels each. The surface roughness increased from 2.1686 μm to 2.6869 μm with an increase in both SON time, SOFF time and a decrease in voltage. The material removal rate increased from 1.272 mm3/min to 1.616 mm3/min with an increase in SON time but a varying effect was observed the SOFF time and voltage were varied. The analysis revealed that the intensity and duration of the spark had an unswerving relation with the concentration of the microcracks and micropores. More microcracks and micropores were seen in the combination of SON = 120 µs, voltage = 30 V. The concentration of the microcracks and micropores could be minimised by using an appropriate parameter setting. Therefore, considering the surface analysis and material removal, the low carbon NiTi alloy is recommended to machine with 110 μs – 55 μs – 30 v (SON – SOFF – V respectively), to achieve better surface roughness with minimal surface damage.
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Authors and Affiliations

Ebenezer George
1
ORCID: ORCID
Adam Khan M.
1
ORCID: ORCID
Chellaganesh Duraipandi
1
Winowlin Jappes J.T.
1
Julfikar Haider
2

  1. School of Automotive and Mechanical Engineering and Centre for Surface Engineering, Kalasalingam Academy of Research and Education, Tamil Nadu, India
  2. Manchester Metropolitan University, Advanced Materials and Surface Engineering (AMSE) Research Centre, Chester Street, M1 5GD, UK
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Abstract

In this research work, the Ti-6Al-4V material was used for the investigation of machining parameters by means of hybrid micro electrical discharge machining to improve the machining process and reduce the negative effects of debris accumulation in the drilled hole. L9 orthogonal array was used in the Taguchi based grey relational analysis to optimize the parameters such as material removal rate and diametrical accuracy of the machining process for Ti-6Al-4V. This work encompasses the design, development, and calibration of the work piece vibration platform and experimental analysis of the process parameters by means of the hybrid micro electrical discharge machining process. The maximum material removal rate and minimum surface roughness was observed at the current value of 2.5 A, pulse on time is 2 µs and pulse off time is 14.5 µs. The maximum material removal rate was observed for the increase in pulse on time with 14.4  µs and 4 A current level. The diametrical accuracy of the microholes was increased while increasing the pulse off time and decreasing the pulse on time. The fluid flow simulation has been conducted to find out the pressure drop and to know the velocity of the flow inside the hole for the effective flushing of the debris during machining.

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Authors and Affiliations

T. Mugilan
M.S. Aezhisai Vallavi
S. Santhosh
D. Sugumar
S. Christopher Ezhil Singh

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