Investigations on Machining Aspects of Inconel 718 During Wire Electro-Discharge Machining (WEDM): Experimental and Numerical Analysis

Wire electro- discharge machining (WEDM) is known as unique cutting in manufacturing industries, especially in the good tolerance with intricate shape geometry in die industry. In this study the workpiece has been chosen as Inconel 718. Inconel 718 super alloy is widely used in aerospace industries. This nickel based super alloy has excellent resistance to high temperature, mechanical and chemical degradations with toughness and work hardening characteristics materials. Due to these properties, the machinability studies of this material have been carried-out in this study. The machining of Inconel 718 using variation of wire electrode material (brass wire electrode and zinc coated brass wire) with diameter equal to 0.20mm has been carried out. The objective of this study is mainly to investigate the various WEDM process parameters and performance of wire electrodes materials on Inconel 718 with various types of cutting. The optimal process parameter setting for each of wire electrode material has been obtained for multi-objective response. The kerf width, Material Removal Rate (MRR) and surface finish, corner error, corner deviation and angular error are the responses which are function of process variables viz. pulse-on time, discharge current, wire speed, flushing pressure and taper angle. The non-linear regression analysis has been developed for relationship between the process parameter and process characteristics. The optimal parameters setting have been carried out using multi-objective nature-inspired meta-heuristic optimization algorithm such as Whale Optimization Algorithm (WOA) and Gray Wolf Optimizer (GWO). Lastly numerical model analysis has been carried out to determine MRR and residual stress using ANSYS software and MRR model validated with the experimental results. The overlapping approach has been adopted for solving the multi-spark problem and validate with the experimental results

Estimating the exchanged energy distribution in micro-EDM

This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro Electro Discharge Machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. The validity of several theoretical crater models was then assessed. Using this approach, the process was analysed for two electrode shapes and two sets of machining parameters. The preliminary results appears to fit those presented in the literature

Experimental and numerical research on some fundamental aspects of the WEDM process

191 p.El corte por electroerosión por hilo (WEDM) es un método no convencional de mecanizado ampliamente utilizado en la fabricación de componentes de alto valor añadido para las industrias aeroespacial,biomédica y automotriz, entre otras. Esto se atribuye a su alta precisión de mecanizado, eficiencia,estabilidad y capacidad de mecanizado de diversas formas complejas. El proceso WEDM se ha utilizado particularmente en aplicaciones de herramientas para el mecanizado de diversos materiales y se ha desarrollado en máquinas de alta tecnología. Sin embargo, todavía existen ciertos aspectos fundamentales relacionados con el proceso de mecanizado que se hacen falta investigar mas al fondo. Para mejorar la calidad y la eficiencia del mecanizado, una comprensión profunda del proceso de mecanizado y de los principios de mecanizado es esencial e indispensable. Esta tesis está dedicada a profundizar en el análisis de algunos aspectos fundamentales del proceso WEDM a través de experimentos, simulación numérica y discusiones relacionadas, y cubre el análisis profundo de todo el proceso de WEDM. Los resultados de este trabajo serán útiles para una mejor comprensión y desarrollo del proceso de mecanizado en el futuro

Approaches for improvement of EDM performance and for the understanding of electrode wear phenomena

165 p.La electroerosión (EDM) es un proceso termo-eléctrico en el que el material se elimina mediante una serie de descargas eléctricas generadas entre el electrodo y la pieza, que se encuentras sumergida en un medio dieléctrico. Son dos los principales tipos de electroerosión empleados hoy en día industrialmente la electroerosión por penetración (SEDM) y la electroerosión por hilo (WEDM. La tesis está centrada en SEDM. Los principales objetivos de la tesis son: - Mejora del rendimiento de corte por SEDM del material SIC con electrodo en forma de lámina de cobre. Para ello se plantean dos tipos de diseño de electrodo con objeto de mejorar el proceso.- Mejorar el rendimiento de EDM en el mecanizado de ranuras de alta relación de aspecto. Para ello se plantea un electrodo convencional al que se le han taladrado agujeros. El objetivo es mejorar la limpieza durante la erosión, consiguiendo así una mejor estabilidad del proceso. Ello conlleva menores tiempos de erosión.- Desarrollo de una metodología para el análisis del desgaste y del gap, basada en indicadores fáciles de aplicar tanto en geometrías sencillas como complejas.- Desarrollo de una metodología que contempla ensayo experimental con simulación térmica, para la definición de la energía absorbida por el electrodo durante la erosión.- Desarrollo de un modelo térmico que define la distribución de temperaturas en el electrodo bajo condiciones industriales

Approaches for improvement of EDM performance and for the understanding of electrode wear phenomena

165 p.La electroerosión (EDM) es un proceso termo-eléctrico en el que el material se elimina mediante una serie de descargas eléctricas generadas entre el electrodo y la pieza, que se encuentras sumergida en un medio dieléctrico. Son dos los principales tipos de electroerosión empleados hoy en día industrialmente la electroerosión por penetración (SEDM) y la electroerosión por hilo (WEDM. La tesis está centrada en SEDM. Los principales objetivos de la tesis son: - Mejora del rendimiento de corte por SEDM del material SIC con electrodo en forma de lámina de cobre. Para ello se plantean dos tipos de diseño de electrodo con objeto de mejorar el proceso.- Mejorar el rendimiento de EDM en el mecanizado de ranuras de alta relación de aspecto. Para ello se plantea un electrodo convencional al que se le han taladrado agujeros. El objetivo es mejorar la limpieza durante la erosión, consiguiendo así una mejor estabilidad del proceso. Ello conlleva menores tiempos de erosión.- Desarrollo de una metodología para el análisis del desgaste y del gap, basada en indicadores fáciles de aplicar tanto en geometrías sencillas como complejas.- Desarrollo de una metodología que contempla ensayo experimental con simulación térmica, para la definición de la energía absorbida por el electrodo durante la erosión.- Desarrollo de un modelo térmico que define la distribución de temperaturas en el electrodo bajo condiciones industriales

Investigating the energy consumption of the PECM process for consideration in the selection of manufacturing process chains

The initial planning of manufacturing process chains provides the opportunity to sustainably influence the energy requirement for the manufacturing of industrial products by selecting the process chain with the lowest energy consumption. However, the task is still challenging due to the need for energy consumption data of manufacturing equipment. In this paper, the analysis of the energy consumption of a manufacturing process is illustrated by the example of the Pulse Electrochemical Machining (PECM) process. A comparison of two machine tool generations of the same manufacturer shows the improvement in energy consumption. Based on the information gained from the analysis, an approach for the provision of energy consumption data is presented

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

AbstractAmong the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiCp/Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiCp/Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiCp/Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiCp/Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiCp/Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications

Estimating the exchanged energy distribution in micro-EDM

This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro Electro Discharge Machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. The validity of several theoretical crater models was then assessed. Using this approach, the process was analysed for two electrode shapes and two sets of machining parameters. The preliminary results appears to fit those presented in the literature