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In this work, machining of Ti-6246 was carried out on EDM using graphite electrode using EDM oil dielectric. The process variables selected were current, pulse on-time and pulse off-time. Design of experiment was based on Box-Behnken Design of RSM technique. Optimization was conducted through desirability approach. Machinability of Ti-6246 work mat...
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... were conducted on the Tool craft die sinking EDM machine; model G30; spark generator type. Fig. 2 pulse generator. Specifications of die sinking EDM are given in Table 2. Polarity of electrode was kept as positive and polarity of work piece was ...
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... this plot. The observation made from this figure indicated that the SR was maximum at I equals to 4.5A and 300 ms T off. Surface plot between SR versus T off and T on is depicted in Fig. 11 while I was kept constant in this plot. The obser- vation made from this figure indicated that SR was very less influenced at T on 100 ms and 300 ms T off . Fig. 12 shows the contour plots between SR versus T on and I while T off was kept constant. Fig. 13 shows the contour plot between SR versus T off and I while T on was kept constant. Fig. 14 shows the contour plot between SR versus T on and T off while I was kept ...
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This study focuses on predictive modeling in machining, specifically material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) prediction using regression analysis. The research employs electrical discharge machining (EDM) experiments to validate the proposed unified predictive model. The approach involves varying machining para...
Citations
... In addition, he studied the impacts of processing factors like cutting speed and wire tension on machining ability and cutting quality features such as cutting velocity, taperness, and kerf width. Thakur et al. [28] Studied EDM machining of titanium alloy by using graphite tool electrode in suitable dielectric medium. Machining performance design is according to proper methods used in performance evaluation. ...
Electrochemical machining plays an important role in production and manufacturing industries like aircraft , atomic and healthcare. Even with difficult-to-machine materials, ECM is generally preferred to machine-nickel-based alloys like Monel 400 or Monel super alloy which consists of about 67 % Nickel and 23 % Copper. It is highly unaffected to corrosion and various acids such as sulphuric acid (H 2 SO 4), hydrochloric acid (HCl) etc. due to which it is highly used in aerospace, oil production and refining, marine applications, industrial heat exchangers. Nowadays nickel hydroxides are major concerns which are toxic to environment present in sludge while machining nickel based alloys like Monel alloys and other super alloys need to be filtered before discharged into environment. This paper reviews the Electrochemical machining of Monel 400 alloy by various influencing parameters like applied voltage, current density, concentration of electrolyte, electrolyte pressure and type of electrolyte on material removal rate (MRR) tool wear rate (TWR) and surface roughness (SR). The study also suggests that the varying process parameters of ECM machining influence the various machining performances such as material removal rate (MRR) tool wear rate (TWR) and Surface finish (Ra) for Monel 400 alloy. In a recent study which utilized meta-heuristic algorithms (MFO and GWO) helped in increasing MRR by 0.242 g/min and Nickel presence by 57.72 PPM while machining Monel 400 and hence a better machining performance is obtained. The paper also aims at addressing the latest developments in machining Monel alloy as compared with conventional methods of machining and its various research challenges for further developments in non-traditional machining processes.
... In addition, he studied the impacts of processing factors like cutting speed and wire tension on machining ability and cutting quality features such as cutting velocity, taperness, and kerf width. Thakur et al. [28] Studied EDM machining of titanium alloy by using graphite tool electrode in suitable dielectric medium. Machining performance design is according to proper methods used in performance evaluation. ...
Electrochemical machining plays an important role in production and manufacturing industries like aircraft, atomic and healthcare. Even with difficult-to-machine materials, ECM is generally preferred to machine-nickel-based alloys like Monel 400 or Monel super alloy which consists of about 67 % Nickel and 23 % Copper. It is highly unaffected to corrosion and various acids such as sulphuric acid (H2SO4), hydrochloric acid (HCl) etc. due to which it is highly used in aerospace, oil production and refining, marine applications, industrial heat exchangers. Nowadays nickel hydroxides are major concerns which are toxic to environment present in sludge while machining nickel based alloys like Monel alloys and other super alloys need to be filtered before discharged into environment. This paper reviews the Electrochemical machining of Monel 400 alloy by various influencing parameters like applied voltage, current density, concentration of electrolyte, electrolyte pressure and type of electrolyte on material removal rate (MRR) tool wear rate (TWR) and surface roughness (SR). The study also suggests that the varying process parameters of ECM machining influence the various machining performances such as material removal rate (MRR) tool wear rate (TWR) and Surface finish (Ra) for Monel 400 alloy. In a recent study which utilized meta-heuristic algorithms (MFO and GWO) helped in increasing MRR by 0.242 g/min and Nickel presence by 57.72 PPM while machining Monel 400 and hence a better machining performance is obtained. The paper also aims at addressing the latest developments in machining Monel alloy as compared with conventional methods of machining and its various research challenges for further developments in non-traditional machining processes.
... Kumar and Rao [38] investigated doing the processing of the of titanium based alloy the while adding of aluminium or silicon carbide in powdered form. Thakur et al. [39] revealed the various concerns regarding various input variables and its effects on the output variables. Amorim et al. [40] investigated the impact of various process variables on the output characteristics during the machining and finally got optimum values. ...
... When figures 4 and 5 are examined, the increases in SR values due to the increase in I p values are clearly seen. It is known that SR values increase with the increase of I p values [24][25][26]. This situation is explained by the increase in spark intensities with the increase in discharge current and the formation of deeper craters on the workpiece surface by the sparks with increasing intensity. ...
Keyed joints are one of the most widely used methods of motion and power transmission. The high functionality and reliability of the joining elements depend on their resistance to the thermo-mechanical stresses that occur during operation and their high precision manufacturing. In this context, a widespread analysis of keyway opening and machining parameters (discharge current, pulse on time and pulse off time) was carried out according to DIN 6885 standard by a die-sinking electrical discharge machine on Ti-4Al-6V alloy with poor machinability. First, the effects of processing parameters on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were investigated by EDM experiments in a kerosene environment. It was seen that the discharge current and the pulse on time have a significant effect on the processing outputs MRR, TWR and SR. In addition, the processed surface and subsurface formations were comprehensively evaluated with SEM and EDS analyses. By reason of the low thermal conductivity of Ti6Al4V, it has been determined that the depth of the heat affected zone reaches 60 µm. In the second stage, mathematical models were developed for the prediction of processing outputs using artificial neural network (ANN) and regression analysis (RA) methods. When these two methods were compared, it was determined that the modelling results with ANN were closer to the experimental results.
... Energy obtained from all sparks is discontinuous and is sufficiently high to cause melting and vaporization of the work sample within the gap. The servo system retains the working gap for continual operation (Khan and Rao, 2019;Thakur et al., 2021). The tool has the shape of desired profile to be made on the workpiece. ...
... Dielectric fluid is an important requirement for the EDM and performs several functions which influence the characteristics of machined products. The functions performed by dielectric include insulation, ionization, cooling, and debris deposition after machining (Khan and Rao, 2019;Khan et al., 2022;Thakur et al., 2021). Thus, the dielectric fluid should be selected carefully. ...
Biodiesel is a chemically modified eco-friendly fuel mainly used as a fuel in compression ignition engines. It is prepared from vegetable oil or animal fat. It is gaining worldwide popularity because it is a renewable, non-toxic, biodegradable, and non-flammable fuel. This paper gives an insight into various aspects of biodiesel. Literature review of biodiesel production, its performance in diesel engine, and the electrical discharge machining process are discussed along with other applications. An innovative biodiesel production plant of 20 litres capacity has been designed and developed successfully. The conversion reaction was carried out for 20 litres of used cooking oil and 4 litres of methanol. The biodiesel production yield of 95.8% was observed for a 1:6 molar ratio of methanol and used cooking oil using 200 gm of KOH catalyst at 60°C for 1 hour. In the second phase of the work, a framework for using biodiesel as a dielectric fluid during spark machining is presented. Using biodiesel during the spark machining process can reduce pollution and also enhances the sustainability of the process.
... Kumar and Rao [38] investigated doing the processing of the of titanium based alloy the while adding of aluminium or silicon carbide in powdered form. Thakur et al. [39] revealed the various concerns regarding various input variables and its effects on the output variables. Amorim et al. [40] investigated the impact of various process variables on the output characteristics during the machining and finally got optimum values. ...
Superalloys are a group of nickel, iron–nickel and cobalt alloys used in various applications. These metals have excellent heat resistant properties and retain their stiffness, strength, toughness and dimensional stability at temperatures much higher than the other aerospace structural materials hence are also known as metal of future. This paper reviews the EDM machining superalloys like Nickel-based superalloys, Cobalt-based superalloys, iron based superalloy also the effect of parameters on MRR, EWR, and surface roughness. The study suggest that current and pulse on time were the most influential parameters, current below 1 A with changing polarity are more effective. Polarity also plays an important role in deciding MRR.
... This shows that the 3Dprinting process is more effective on improved surfaces when printing flat specimens than complex shapes. The Rq and Sq results compared favourably to previous studies of the surface treatment performance of TI6AI 4V produced by additive manufacturing (Mostafaei et al. 2018;Thakur et al. 2020). The root mean square (Rq and Sq) parameters are the simplest and most widely used amplitude parameters (Khan and Rahman 2017;Kozior and Bochnia 2020). ...
The initial stability after implantology is paramount to the survival of the dental implant, and the surface roughness of the implant plays a vital role in this regard. The characterisation of surface topography is a complicated branch of metrology, with a huge range of parameters available. Each parameter contributes significantly towards the survival and mechanical properties of three-dimensional printed specimens. The purpose of this paper is to experimentally investigate the effect of surface roughness of three-dimensional printed dental implants and three-dimensional printed dogbone tensile samples under areal height parameters, amplitude parameters (average of ordinates), skewness parameters and mechanical properties. During the experiment, roughness values were analysed, and the results showed that the skewness parameter demonstrated a minimum value of 0.59%. The three-dimensional printed dental implant recorded the arithmetic mean deviation of the assessed profile with a 3.4-mm diameter at 43.23% and the three-dimensional printed dental implant with a 4.3-mm diameter at 26.18%. Samples with a complex geometry exhibited a higher roughness surface, which was the greatest difficulty of additive manufacturing when evaluating surface finish. The results show that when the ultimate tensile stress decreases from 968.35 to 955.25 MPa, the arithmetic mean deviation increases by 1.4%, and when ultimate tensile stress increases to 961.18 MPa, the arithmetic mean deviation increases by 0.6%. When the cycle decreases from 262,142 to 137,433, the arithmetic mean deviation shows that less than a 90.74% increase in the cycle is obtained. For the three-dimensional printed dental implants, the higher the surface roughness, the lower the mechanical properties, ultimately leading to decreased implant life and poor performance.
... This shows that the 3D-printing process is more effective on improved surfaces when printing flat specimens than complex shapes. The Rq and Sq results compared favourably to previous studies of the surface treatment performance of TI6AI 4V produced by additive manufacturing [36], [37]. The root mean square (Rq and Sq) parameters are the simplest and most widely used amplitude parameters [7], [35]. ...
The initial stability after implantology is paramount to the survival of the dental implant and the surface roughness of the implant plays a vital role in this regard. The characterisation of surface topography is a complicated branch of metrology, with a huge range of parameters available. Each parameter contributes significantly towards the survival and mechanical properties of 3D-printed specimens. The purpose of this paper is to experimentally investigate the effect of surface roughness of 3D-printed dental implants and 3D-printed dogbone tensile samples under areal height (Ra) parameters, amplitude parameters (average of ordinates), skewness (Rsk) parameters and mechanical properties. During the experiment, roughness values were analysed and the results showed that the skewness parameter demonstrated a minimum value of 0.596%. The 3D-printed dental implant recorded Ra with a 3.4 mm diameter at 43.23% and the 3D-printed dental implant with a 4.3 mm diameter at 26.18%. Samples with a complex geometry exhibited a higher roughness surface, which was the greatest difficulty of additive manufacturing when evaluating surface finish. The results show that when the ultimate tensile stress (UTS) decreases from 968.35 MPa to 955.25 MPa, Ra increases by 1.4% and when UTS increases to 961.18 MPa, Ra increases by 0.6%. When the cycle decreases from 262142 to 137433, Ra shows that less than a 90.74% increase in cycle is obtained. For 3D-printed dental implants, the higher the surface roughness, the lower the mechanical properties , ultimately leading to decreased implant life and poor performance.
The interfacial heat transfer coefficient (IHTC) formed at the casting-mould interface is an important parameter to affect the quality of cast product. Hence, the present study aims to perform the heat transfer analysis on the interface of mould and casting. The effect of pouring temperature and the properties of the cast metal were investigated by evaluating interfacial heat flux and interfacial heat transfer coefficient (IHTC) using transient temperatures inside the mould and casting. During the experiments, transient temperatures inside the mould and casting are recorded. Effects of pouring temperature, casting material and mould material on the transient heat flux and IHTC are also studied. From the results, both interfacial heat flux and interfacial heat transfer coefficient are found to be increasing with increase in pouring temperature keeping all other parameters constant. At same pouring temperature, interfacial heat flux is found to be independent of casting material, whilst IHTC is found to be dependent on the properties of casting material. Peak value of IHTC is found to be much higher in case of zinc metal casting as compared to aluminium metal casting. Novel and physically based analytical interpretation of the results is provided. The results will be useful for metal forming industries to develop better castings at lower costs.
Die sinking EDM of Ti6Al4V has been carried out with copper tungsten electrode. The Input current (Ip), Pulse on Time (Ton) and Spark Gap Voltage (Sv) have been taken as the input factors. The MRR, EWR, and Ra have been optimized. The Response Surface Methodology (Box-Bhenken Design) has been used as DOE for analysis and optimization. The three levels of input factors has been taken as per DOE, Input current (Ip), Pulse on Time (Ton), Spark Gap Voltage (Sv), and the levels were taken on which, machining has been performed, i.e., 10 A, 15 A, 20 A, 100 µs, 150 µs, 200 µs, 15 V, 20 V, and 25 V. The analysis of variance has been performed for MRR, EWR, and Ra by RSM, Quadratic equations for model analysis and 3D surface models have been optimized by RSM.KeywordsEDM
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