Commenced in January 2007
Paper Count: 30840
An Experimental Study on the Effect of Operating Parameters during the Micro-Electro-Discharge Machining of Ni Based Alloy
Abstract:Ni alloys have managed to cover wide range of applications such as automotive industries, oil gas industries, and aerospace industries. However, these alloys impose challenges while using conventional machining technologies. On the other hand, Micro-Electro-Discharge machining (micro-EDM) is a non-conventional machining method that uses controlled sparks energy to remove material irrespective of the materials hardness. There has been always a huge interest from the industries for developing optimum methodology and parameters in order to enhance the productivity of micro-EDM in terms of reducing machining time and tool wear for different alloys. Therefore, the aims of this study are to investigate the effects of the micro-EDM process parameters, in order to find their optimal values. The input process parameters include voltage, capacitance, and electrode rotational speed, whereas the output parameters considered are machining time, entrance diameter of hole, overcut, tool wear, and crater size. The surface morphology and element characterization are also investigated with the use of SEM and EDX analysis. The experimental result indicates the reduction of machining time with the increment of discharge energy. Discharge energy also contributes to the enlargement of entrance diameter as well as overcut. In addition, tool wears show reduction with the increase of discharge energy. Moreover, crater size is found to be increased in size along with the increment of discharge energy.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1127418Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 922
 Wright, P.K. and E.M. Trent, Metal cutting. 2000: Butterworth-Heinemann.
 Axinte, D., et al., Turning of advanced Ni based alloys obtained via powder metallurgy route. CIRP Annals-Manufacturing Technology, 2006. 55(1): p. 117-120.
 Komvopoulos, K. and S. Erpenbeck, Finite element modeling of orthogonal metal cutting. Journal of Engineering for Industry, 1991. 113(3): p. 253-267.
 Jianxin, D. and A. Xing, Wear behavior and mechanisms of alumina-based ceramic tools in machining of ferrous and non-ferrous alloys. Tribology international, 1997. 30(11): p. 807-813.
 Tsai, H., B. Yan, and F. Huang, EDM performance of Cr/Cu-based composite electrodes. International Journal of Machine Tools and Manufacture, 2003. 43(3): p. 245-252.
 Masuzawa, T., State of the art of micromachining. CIRP Annals-Manufacturing Technology, 2000. 49(2): p. 473-488.
 Tsai, Y.-Y. and T. Masuzawa, An index to evaluate the wear resistance of the electrode in micro-EDM. Journal of Materials Processing Technology, 2004. 149(1): p. 304-309.
 Ho, K. and S. Newman, State of the art electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture, 2003. 43(13): p. 1287-1300.
 Liu, H.-S., et al., A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications. Journal of Materials Processing Technology, 2005. 169(3): p. 418-426.
 Masuzawa, T., J. Tsukamoto, and M. Fujino, Drilling of Deep Microholes by EDM. CIRP Annals - Manufacturing Technology, 1989. 38(1): p. 195-198.
 Daneshmand, S., et al., Influence of machining parameters on electro discharge machining of NiTi shape memory alloys. Int. J. Electrochem. Sci, 2013. 8(3): p. 3095-3104.
 Rasheed, M.S., et al., Analysis of influence of micro-EDM parameters on MRR, TWR and Ra in Machining Ni-Ti shape memory alloy. International Journal of Recent Technology and Engineering, 2012. 1(4): p. 32-37.
 Theisen, W. and A. Schuermann, Electro discharge machining of nickel–titanium shape memory alloys. Materials Science and Engineering: A, 2004. 378(1): p. 200-204.
 Chen, S., et al., Electrical discharge machining of TiNiCr and TiNiZr ternary shape memory alloys. Materials Science and Engineering: A, 2007. 445: p. 486-492.
 Lin, H., K. Lin, and Y. Chen, A study on the machining characteristics of TiNi shape memory alloys. Journal of Materials Processing Technology, 2000. 105(3): p. 327-332.
 Daneshmand, S., et al., Experimental Investigations into Electro Discharge Machining of NiTi Shape Memory Alloys using Rotational Tool. Int. J. Electrochem. Sci, 2013. 8: p. 7484-7497.
 Al-Ahmari, A., et al., A Hybrid Machining Process Combining Micro-EDM and Laser Beam Machining of Nickel–Titanium-Based Shape Memory Alloy. Materials and Manufacturing Processes, 2016. 31(4): p. 447-455.
 Dwivedi, A.P. and S.K. Choudhury, Effect of Tool Rotation on MRR, TWR and Surface Integrity of AISI-D3 Steel using Rotary EDM Process. Materials and Manufacturing Processes, 2016(just-accepted).
 Jahan, M.P., Y.S. Wong, and M. Rahman, A comparative experimental investigation of deep-hole micro-EDM drilling capability for cemented carbide (WC-Co) against austenitic stainless steel (SUS 304). The International Journal of Advanced Manufacturing Technology, 2010. 46(9): p. 1145-1160.