Influence of Process Parameters on Electrochemical Micromachining of Nimonic 75 Alloy

2017 ◽  
Author(s):  
Hariharan Perianna Pillai ◽  
Shamli Chinnakulanthai Sampath ◽  
Rajkeerthi Elumalai ◽  
Shruthilaya Hariharan ◽  
Yuvaraj Natarajan
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cycle Performance ◽  
Electrochemical Micromachining ◽  
Influence Of Process Parameters ◽  
Micro Hole ◽  
Micro Tool ◽  
Nimonic 75

Electrochemical micromachining process is one among the successful micromachining technique, which uses the electrochemical energy and is recognized for machining difficult-to-cut materials. One such material is Nimonic 75 alloy, which is used to make gas turbine components. In this study, an effort has been made to machine micro-hole profiles in Nimonic 75 with a thickness of 500 μm using two different electrolytes. A combination of sodium bromide, hydrofluoric acid and ethylene glycol has been chosen as the first electrolyte, while the second is a combination of sodium chloride and sodium nitrate. Solid tungsten carbide of diameter 500 μm is used as the tool in each case. For layout of experiments, Taguchi orthogonal array was chosen with following input parameters namely voltage, micro-tool feed rate and duty cycle. Performance characteristics such as material removal rate, overcut and conicity have been assessed for each electrolyte. Experimental results have shown that the first electrolyte yields lower values of overcut (OC) and conicity, whereas the second electrolyte gives higher material removal rate (MRR). Further, the optimal combinations of process parameters have been found by implementing the TOPSIS procedure and the results were found to be in good agreement with the experimental outcomes.

Modeling and Analysis of Process Parameters on State Variables in WEDM of TiB2 Nanocomposite Ceramic

2010 ◽  
Vol 34-35 ◽  
pp. 631-635 ◽  
Author(s):  
M. Reza ◽  
Soleymani Yazdi ◽  
Hoseyn Dehghan ◽  
Hoda Amini
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
State Variables ◽  
Influence Of Process Parameters ◽  
Modeling And Analysis

The main objective of the present research is to find the influence of process parameters on the state variables (i.e., surface roughness and material removal rate) in Wire Electrical Discharge Machining (WEDM) of Titanium Diboride (TiB2) nanocomposite ceramics. This work adopted an L32 orthogonal array based on Taguchi method for design of experiments. Statistically evaluating the obtained data is carried out by using the analysis of variance, signal to noise and artificial neural network techniques. Then, the effects of process parameters on the surface roughness and material removal rate are studied. Finally, the Multilayer Perceptron (MLP) neural network is used to model the WEDM of TiB2 nanocomposite ceramic. The obtained results have demonstrated very good modeling capacity of the proposed neural network. Furthermore, analyses have appropriately presented the influence of process parameters on state variables.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

2018 ◽  
Vol 233 (6) ◽  
pp. 1896-1909 ◽  
Author(s):  
VG Ladeesh ◽  
R Manu
Keyword(s):  
Material Removal Rate ◽  
Borosilicate Glass ◽  
Chemical Etching ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Hybrid Technique ◽  
Machined Surface ◽  
Influence Of Process Parameters ◽  
Electrochemical Discharge

The electrically non-conductive materials like glass, ceramics, quartz, etc. are of great interest for many applications in modern industries. Machining them with high quality and at a faster rate is a challenging task. In this study, a novel technique called grinding aided electrochemical discharge drilling (G-ECDD) is demonstrated which uses a hollow diamond core drill as the tool for performing electrochemical discharge machining of borosilicate glass. The new hybrid technique enhances the material removal rate and machining accuracy to several folds by combining the thermal melting action of discharges and grinding action of the abrasive tool. This paper presents the experimental investigation on the material removal rate during G-ECDD of glass while using different electrolytes. An attempt has been made to explore the influence of electrolyte temperature on G-ECDD performance by maintaining the electrolyte at different temperatures. Experiments were conducted using three different electrolytes which include NaOH, KOH, and the mixture of both. The results obtained from this study revealed that an increase in temperature will favor chemical etching as well as electrochemical reaction rate. Also, it was observed that heating the electrolyte leads to an increase in the bubble density and enhances the ion mobility. This causes the formation of gas film at a faster rate and thereby improving the discharge activity. Thus, machining will be done at a faster rate. Better results are obtained while using a mixture of NaOH and KOH. From the microscopic images of the machined surface, it was observed that material removal mechanism in G-ECDD is a combination of grinding action, electrochemical discharges, and chemical etching. Response surface methodology was adopted for studying the influence of process parameters on the performance of G-ECDD. The new technique of grinding aided electrochemical discharge drilling proved its potential to machine borosilicate glass and simultaneously offers good material removal rate, repeatability, and accuracy.

Optimization of Process Parameters in Plasma Arc Cutting Applying Genetic Algorithm and Fuzzy Logic

2018 ◽  
pp. 123-139
Author(s):  
Nehal Dash ◽  
Apurba Kumar Roy ◽  
Sanghamitra Debta ◽  
Kaushik Kumar
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Fuzzy Logic ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Plasma Arc ◽  
Plasma Arc Cutting ◽  
Optimization Of Process Parameters

Plasma Arc Cutting (PAC) process is a widely used machining process in several fabrication, construction and repair work applications. Considering gas pressure, arc current and torch height as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness would be considered as factors that determines the quality, machining time and machining cost. In order to reduce the number of experiments Design of Experiments (DOE) would be carried out. In later stages applications of Genetic Algorithm (GA) and Fuzzy Logic would be used for Optimization of process parameters in Plasma Arc Cutting (PAC). The output obtained would be minimized and maximized for Surface Roughness and Material Removal Rate respectively using Genetic Algorithm (GA) and Fuzzy Logic.

Effect of WEDM process parameters on machinability of Nimonic75 alloy using brass wire

2020 ◽  
Vol 17 (3) ◽  
pp. 389-397
Author(s):  
Harvinder Singh ◽  
Vinod Kumar ◽  
Jatinder Kapoor
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Content Type ◽  
Response Characteristics ◽  
Nickel Based Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Purpose This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly used in the aerospace industry for its strength at high temperature. Design/methodology/approach One factor at a time (OFAT) approach has been used to perform the experiments. Pulse on time, pulse off time, peak current and servo voltage were chosen as input process parameters. Cutting speed, material removal rate and surface roughness (Ra) were selected as output performance characteristics. Findings Through experimental work, the effect of process parameters on the response characteristics has been found. Results identified the most important parameters to maximize the cutting speed and material removal rate and minimize Ra. Originality/value Very limited research work has been done on WEDM of Nickel-based alloy Nimonic75. Therefore, the aim of this paper to conduct preliminary experimentation for identifying the parameters, which influence the response characteristics such as material removal rate, cutting speed, Ra, etc. during WEDM of Nickel-based alloy (Nimonic75) using OFAT approach and found the machinability of Nimonic75 for further exhaustive experimentation work.

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