Books and journals Case studies Expert Briefings Open Access
Advanced search

Search results

1 – 10 of 57
To view the access options for this content please click here
Article
Publication date: 13 July 2020

Sustainable processing of Inconel 718 super alloy in electrical discharge machining process

Ruben Phipon, Ishwer Shivakoti and Ashis Sharma

This paper aims to present the performance of deionized water in electrical discharge machining (EDM) during machining of Inconel 718, copper tool electrode and deionized…

HTML
PDF (1.8 MB)

Abstract

Purpose

This paper aims to present the performance of deionized water in electrical discharge machining (EDM) during machining of Inconel 718, copper tool electrode and deionized water as dielectric. Three parameters, namely, pulse-on-time, pulse-off-time and discharge current were taken as control parameters with individual parameter having three levels. Influence of these control parameters on response such as tool wear rate (TWR), material removal rate (MRR) and surface roughness (Ra) is evaluated at various combinations of parametric levels. The results reveal deionized water can be effectively used as a sustainable dielectric and may substitute the hydrocarbon-based dielectric in electrical discharge machining. Also, the control parameters considered show significant impact on the process criteria. Super ranking method was adopted to achieve optimal integration of EDM control factors for obtaining higher MRR, lower TWR and Ra. Further, by applying analysis of variance test, discharge current is established as the dominant parameter during the machining process.

Design/methodology/approach

The experimentation was performed on Inconel 718 in SPARKONIX MOS, 35 A, ZNC EDM using deionized water as dielectric and copper tool as electrode. The dielectric circulatory system was developed without disturbing the existing dielectric circulation system. Figure 1 shows the EDM with newly developed dielectric system. The existing system consists of hydrocarbon-based dielectric, which has a number of drawbacks during the machining such as carbide deposition on the work material, which reduces removal of material from work material; carbon particle adhesion on tool, which results in inefficient discharge between the electrode; and the work material and production of CO and CH4 during machining, which makes the machining environment toxic. To overcome these drawbacks, a sustainable dielectric was adopted in present work. Trial experiments were conducted to select the ranges of parameters, namely, discharge current, pulse-on-time and pulse-off-time. The process characteristics were evaluated at different parametric combinations and the experimentation was designed as per Taguchi L9 orthogonal array. Table 1 shows the properties of Inconel 718. Table 2 shows the parameters considered with its ranges. Table 3 shows the experimental values. The difference of weight of work piece before and after was taken and divided by the machining time used for calculating the MWR. Similarly, the difference of weight of tool material before and after was taken and divided by machining time and is used for calculating TWR. Measurement of surface roughness was done using Talysurf surface roughness meter.

Findings

The experimentation was conducted at different parametric combination on Inconel 718 taking copper as electrode and deionized water as dielectric. The performance criteria was evaluated at considered parametric combination. The result shows that the EDM parameters have significant contribution on the performance criteria and deionized water can be effectively used as dielectric medium in EDM. The use of deionized water as dielectric will improve the process and sustainable green machining can be performed. Super ranking method has been implemented to achieve the best combination of control factors and it is obtained that the combination A1B1C3 (i.e. discharge current = 3 A, pulse-on-time = 1 µs and pulse-off-time = 3 µs) is best combination for obtaining the higher MRR and lower TWR and Ra. The contributing factor in the proposed research work is discharge current. Further, ANOVA was implemented to check the adequacy of these result. It was established that discharge current is the most influential factor followed by pulse-on-time and the least contributing factor as pulse-off-time. The findings of this paper may open the guidelines for researcher for performing research in the field of sustainable machining of difficult to cut materials such as Inconel 718 with sustainable dielectrics in engineering applications.

Originality/value

The paper is original in nature. The findings of this paper may open the guidelines for researcher for performing research in the field of sustainable machining.

Details

World Journal of Engineering, vol. 17 no. 5
Type: Research Article
DOI: https://doi.org/10.1108/WJE-03-2020-0077
ISSN: 1708-5284

Keywords

  • Discharge
  • Inconel718
  • EDM
  • MRR
  • TWR

To view the access options for this content please click here
Article
Publication date: 28 June 2019

Influence of ceramic Al2O3 particulates on performance measures and surface characteristics during sinker EDM of stir cast AMMCs

Akhil Khajuria, Modassir Akhtar, Manish Kumar Pandey, Mayur Pratap Singh, Ankush Raina, Raman Bedi and Balbir Singh

AA2014 is a copper-based alloy and is typically used for production of complex machined components, given its better machinability. The purpose of this paper was to study…

HTML
PDF (3.2 MB)

Abstract

Purpose

AA2014 is a copper-based alloy and is typically used for production of complex machined components, given its better machinability. The purpose of this paper was to study the effects of variation in weight percentage of ceramic Al2O3 particulates during electrical discharge machining (EDM) of stir cast AA2014 composites. Scanning electron microscopy (SEM) examination was carried out to study characteristics of EDMed surface of Al2O3/AA2014 composites.

Design/methodology/approach

The effect of machining parameters on performance measures during sinker EDM of stir cast Al2O3/AA2014 composites was examined by “one factor at a time” (OFAT) method. The stir cast samples were obtained by using three levels of weight percentage of Al2O3 particulates, i.e. 0 Wt.%, 10 Wt.% and 20 Wt.% with density 1.87 g/cc, 2.35 g/cc and 2.98 g/cc respectively. Machining parameters varied were peak current (1-30 amp), discharge voltage (30-100 V), pulse on time (15-300 µs) and pulse off time (15-450 µs) to study their influence on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR).

Findings

MRR and SR decreased with an increase in weight percentage of ceramic Al2O3 particulates at the expense of TWR. This was attributed to increased microhardness for reinforced stir cast composites. However, microhardness of EDMed samples at fixed values of machining parameters, i.e. 9 amp current, 60 V voltage, 90 µs pulse off time and 90 µs pulse on time reduced by 58.34, 52.25 and 46.85 per cent for stir cast AA2014, 10 Wt.% Al2O3/AA2014 and 20 Wt.% Al2O3/AA2014, respectively. SEM and quantitative energy dispersive spectroscopy (EDS) analysis revealed ceramic Al2O3 particulate thermal spalling in 20 Wt.% Al2O3/AA2014 composite. This was because of increased particulate weight percentage leading to steep temperature gradients in between layers of base material and heat affected zone.

Originality/value

This work was an essential step to assess the machinability for material design of Al2O3 reinforced aluminium metal matrix composites (AMMCs). Experimental investigation on sinker EDM of high weight fraction of particulates in AA2014, i.e. 10 Wt.% Al2O3 and 20 Wt.% Al2O3, has not been reported in archival literature. The AMMCs were EDMed at variable peak currents, voltages, pulse on and pulse off times. The effects of process parameters on MRR, TWR and SR were analysed with comparisons made to show the effect of Al2O3 particulate contents.

Details

World Journal of Engineering, vol. 16 no. 4
Type: Research Article
DOI: https://doi.org/10.1108/WJE-01-2019-0015
ISSN: 1708-5284

Keywords

  • Stir casting
  • Surface topography
  • Al2O3/AA2014 composite
  • Aluminium alloy 2014
  • MRR
  • TWR
  • SR
  • Hardness
  • Sinker EDM

To view the access options for this content please click here
Article
Publication date: 9 April 2018

Investigating the performance of powder mixed electric discharge machining of Nimonic 75 by using different tool materials

Ramesh S. and Jenarthanan M.P.

This study aims to focus on experimenting the performance of aluminum (Al) powder mixed electric discharge machining (PMEDM) of two different materials viz plastic mould…

HTML
PDF (665 KB)

Abstract

Purpose

This study aims to focus on experimenting the performance of aluminum (Al) powder mixed electric discharge machining (PMEDM) of two different materials viz plastic mould die steel (AISI P20) and nickel-based super alloy (Nimonic 75). This experimental study also focuses on using three different tool materials such as copper, brass and tungsten to analyze their influence on the process output. These materials find many uses in industrial as well as aerospace applications. The performance measures considered in this work are material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR).

Design/methodology/approach

The experimental design used in this work is based on Taguchi’s L18 orthogonal array. Besides considering work and tool material as one of the process variables, other process variables are peak current (Ip), pulse on time (Ton) and concentration of powder (Cp). The analysis of variance (ANOVA) is performed on the experimental data to determine the significant variables that influence the output.

Findings

It is found that copper produced maximum MRR and brass tool exhibited higher TWR. However, the surface finish of the machined work piece was very much improved by using the brass tool. Though the performance of tungsten tool lies between the above two tool materials, it showed very little wear during EDM with or without the addition of Al powder.

Originality/value

The experimental investigation of PMEDM of nickel-based super alloy (Nimonic 75) has not been attempted before. Besides that, the study on the influence of tungsten tool on the performance of EDM is also very limited.

Details

World Journal of Engineering, vol. 15 no. 2
Type: Research Article
DOI: https://doi.org/10.1108/WJE-03-2017-0045
ISSN: 1708-5284

Keywords

  • ANOVA
  • Taguchi
  • AISI P20 steel
  • Nimonic 75
  • Powder mixed EDM
  • Tungsten tool

To view the access options for this content please click here
Article
Publication date: 1 July 2019

Powder mixed electric discharge machining of high-speed steel T1 grade: Optimize through grey relational analysis

Kanwal Jit Singh

The purpose of this paper is to represent the innovative process of powder-mixed electrical discharge machining of high-speed steel T1 grade and to conduct experimental…

HTML
PDF (697 KB)

Abstract

Purpose

The purpose of this paper is to represent the innovative process of powder-mixed electrical discharge machining of high-speed steel T1 grade and to conduct experimental investigation to optimize the machining parameters associated with multiple performance characteristics using grey relational analysis. The machining of high-speed steel T1 grade via conventional machining is a difficult process. However, it can be easily machined by powder-mixed electric discharge machining.

Design/methodology/approach

Carefully selected machining parameters give the optimum output results. For experimentation, the following input parameters have been used: pulse on-time, discharge current, tool material and powder concentration. The effects of input parameters, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR), have been investigated in this research.

Findings

Grey relational analysis and analysis of variance have been performed to optimize the input parameters for better output response. Optimized results show increment of TWR, MRR and SR, which is 63.24, 52.18 and 42.49 per cent, respectively.

Originality/value

This research paper will be beneficial for the industrial application. The GRA result gives the better output response.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 4
Type: Research Article
DOI: https://doi.org/10.1108/MMMS-03-2018-0039
ISSN: 1573-6105

Keywords

  • Electric discharge machining
  • Powder-mixed EDM
  • High-speed steel
  • Grey relational analysis (GRA)

To view the access options for this content please click here
Article
Publication date: 1 August 2006

Optimization of EDM machining parameters using DMLS electrode

Vijay Kumar Meena and Nagahanumaiah

The purpose of this paper is to optimise the electro‐discharge machining (EDM) parameters and investigate feasibility of using direct metal laser sintering (DMLS) parts as…

HTML
PDF (407 KB)

Abstract

Purpose

The purpose of this paper is to optimise the electro‐discharge machining (EDM) parameters and investigate feasibility of using direct metal laser sintering (DMLS) parts as EDM electrodes.

Design/methodology/approach

In this paper the effects of discharge current, pulse‐on‐time, flushing pressure are optimized for minimum tool wear rate (TWR), maximum metal removal rate (MRR) and minimum surface roughness (Ra). Taguchi‐based L9 orthogonal array has been used for performing experiments on EDM machining of EN 24 steel using DMLS electrodes. The grey relational analysis combined with ANOVA techniques have been employed to determine the optimal level as well as their significance.

Findings

Experimental results have shown that the performance characteristics of the EDM process (TWR, MRR and surface roughness) using DMLS electrode can be quantified and controlled effectively by grey relational approach presented in the study. Current is found to be the most affective parameter in EDM machining using DMLS electrode. Excessive DMLS tool (electrode) wear was also reported, which limits the use of DMLS tool for EDM machining and it has been found out that porosity (which was about 20 per cent) was one of the primary cause.

Research limitations/implications

This paper was focused on understanding the effects of important EDM parameters on three performance characteristics (TWR, MRR and surface roughness). While this study identifies that DMLS electrode wear rate is high and porosity could be one of the main cause, presently it does not cover the investigations on reducing the porosity level and its implications.

Practical implications

The DMLS material had shown huge potential to be used as EDM electrode. The current investigation established a structured experimental approach to understand the effects of EDM parameters on multi response characteristics. The results derived from this study helps to focus future research on two aspects including enriching the copper content and reducing the porosity level, thereby the benefits of lead time reduction in EDM electrode making could be realized.

Originality/value

The previous research attempts were not focussed on optimising the EDM machining process using rapid tooling electrodes. With the best of author's knowledge none of the researchers have reported these aspects especially for DMLS electrodes. Application of grey relational analysis for performance evaluation of rapid tooling‐based EDM electrodes (DMLS electrodes) appear to be completely new.

Details

Rapid Prototyping Journal, vol. 12 no. 4
Type: Research Article
DOI: https://doi.org/10.1108/13552540610682732
ISSN: 1355-2546

Keywords

  • Machining centres
  • Sintering
  • Electromechanical devices
  • Optimization techniques

To view the access options for this content please click here
Article
Publication date: 3 September 2018

Experimental investigation of powder-mixed electric discharge machining of AISI P20 steel using different powders and tool materials

Ramesh S., M.P. Jenarthanan and Bhuvanesh Kanna A.S.

The purpose of this paper is to investigate the performance of powder-mixed electric discharge machining (PMEDM) using three different powders which are aluminium (Al)…

HTML
PDF (947 KB)

Abstract

Purpose

The purpose of this paper is to investigate the performance of powder-mixed electric discharge machining (PMEDM) using three different powders which are aluminium (Al), silicon carbide (SiC) and aluminium oxide (Al2O3). Besides that, the influence of different tool materials was also studied in this experimental investigation. Hence, the work material selected for this purpose was AISI P20 steel and tool materials were copper, brass and tungsten. The performance measures considered in this work were material removal rate (MRR), tool wear rate and radial over cut (ROC).

Design/methodology/approach

The process variables considered in this study were powder types, powder concentration, tool materials, peak current and pulse on time. The experimental design, based on Taguchi’s L27 orthogonal array, was adopted to conduct experiments. Significant parameters were identified by performing the analysis of variance on the experimental data.

Findings

Based on the analysis of results, it was observed that copper tool combined with Al powder produced maximum MRR (58.35 mm3/min). Similarly, the Al2O3 powder combined with tungsten tool has resulted least ROC (0.04865 mm). It was also observed that wear rate of tungsten tool was very low (0.0145 mm3/min).

Originality/value

The experimental investigation of PMEDM involving three different powders (Al, SiC and Al2O3) was not attempted before. Moreover, the study of influence of different tool materials (Cu, brass and W) together with the different powders on the electric discharge machining performance was very limited.

Details

Multidiscipline Modeling in Materials and Structures, vol. 14 no. 3
Type: Research Article
DOI: https://doi.org/10.1108/MMMS-04-2017-0025
ISSN: 1573-6105

Keywords

  • ANOVA
  • Tungsten tool
  • AISI P20 steel
  • PMEDM
  • Radial over cut
  • Tungsten
  • Powder-mixed EDM
  • SiC
  • Al2O3

To view the access options for this content please click here
Article
Publication date: 3 December 2018

Ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining of glass: a review paper

Kanwal Jit Singh, Inderpreet Singh Ahuja and Jatinder Kapoor

This review paper reveals the literature on ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining (USM) of glass material. The purpose of this review…

HTML
PDF (3.2 MB)

Abstract

Purpose

This review paper reveals the literature on ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining (USM) of glass material. The purpose of this review paper is to understand and describe the working principle, mechanism of material removal, experimental investigation, applications and influence of input parameters on machining characteristics. The literature reveals that the ultrasonic machines have been generally preferred for the glass and brittle work materials. Some other non-traditional machining processes may thermally damage the work surface. Through these USM, neither thermal effects nor residual stresses have been generated on the machined surface.

Design/methodology/approach

Various input parameters have the significant role in machine performance characteristics. For the optimization of output response, several input parameters have been critically investigated by the various researcher.

Findings

Some advance types of glasses such as polycarbonate bulletproof glass, acrylic heat-resistant glass and glass-clad polycarbonate bulletproof glass still need some further investigation because these materials have vast applications in automobile, aerospace and space industries.

Originality/value

Review paper will be beneficial for industrial application and the various young researcher. Paper reveals the detail literature review on traditional ultrasonic, chemical assisted ultrasonic and rotary USM of glass and glass composite materials.

Details

World Journal of Engineering, vol. 15 no. 6
Type: Research Article
DOI: https://doi.org/10.1108/WJE-04-2018-0114
ISSN: 1708-5284

Keywords

  • Ultrasonic
  • Acrylic
  • Bulletproof
  • Heat resistant
  • Poly-carbonate
  • Surface finish

To view the access options for this content please click here
Article
Publication date: 26 October 2020

Multi-response optimization of EDM parameters using grey relational analysis (GRA) for Ti-5Al-2.5Sn titanium alloy

Munmun Bhaumik and Kalipada Maity

In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process…

HTML
PDF (673 KB)

Abstract

Purpose

In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process parameters. The purpose of this paper is to find out the optimal process parameters setting for getting higher machining efficiency.

Design/methodology/approach

For experimental design, a face-centered central composite design (FCCCD)-based response surface methodology (RSM) is used. Multi-objective optimization like grey relational analysis (GRA) is adopted to achieve the higher machining efficiency by means of lower radial overcut (ROC), surface roughness (Ra), tool wear rate (TWR) and higher material removal rate (MRR). For the statistical study, analysis of variance (ANOVA) has been carried out.

Findings

The result shows that gap voltage, peak current and pulse on time are the most efficient parameters for the responses. An optimal parameter setting has been obtained for achieving higher machining efficiency. For validation of the study, confirmation experiment has been performed at optimal parameters setting.

Originality/value

Optimum parameter level for higher machining performance of Ti-5Al-2.5Sn Titanium alloy has been achieved machined by copper electrode during EDM operation.

Details

World Journal of Engineering, vol. 18 no. 1
Type: Research Article
DOI: https://doi.org/10.1108/WJE-06-2020-0210
ISSN: 1708-5284

Keywords

  • Multi-objective optimization
  • Response surface methodology
  • Electro discharge machining
  • Grey relational analysis (GRA)

To view the access options for this content please click here
Book part
Publication date: 9 December 2016

Using Tourism as a Mechanism to Reduce Poaching and Hunting: A Case Study of the Tidong Community, Sabah

Fiffy Hanisdah Saikim, Bruce Prideaux, Maryati Mohamed and Zulhazman Hamzah

In Sabah, Malaysia, illegal hunting has increased in recent years putting considerable pressure on large mammal populations. The causes for this phenomenon lie in…

HTML
PDF (489 KB)
EPUB (242 KB)

Abstract

In Sabah, Malaysia, illegal hunting has increased in recent years putting considerable pressure on large mammal populations. The causes for this phenomenon lie in increasing rural poverty, ineffective policies to regulate hunting, as well as a ready market for many wildlife products in the Chinese medicine markets. This paper examines how Community-Based Ecotourism has some potential to be used as a tool to reducing poaching using the Tidong community in Sabah as a case study. The key finding is that successful conservation outcomes for Community-Based Ecotourism projects are only sustainable over the long run if projects are structured to ensure that the local community is able to continue effective management once sponsoring organizations hand over control and that revenue from tourism does not decline. If tourist revenue declines communities may be forced to revert to previous practices reversing any initial conservation gains.

Details

Advances in Hospitality and Leisure
Type: Book
DOI: https://doi.org/10.1108/S1745-354220160000012010
ISBN: 978-1-78635-615-4

Keywords

  • Wildlife
  • poaching
  • hunting
  • Tabin wildlife reserve
  • Borneo
  • community-based ecotourism

To view the access options for this content please click here
Article
Publication date: 16 November 2012

Performance study of various tool materials for electrical discharge machining of hot pressed ZrB2

S. Sivasankar, R. Jeyapaul and V.V. Bhanu Prasad

This study aims to explore the machinability of ZrB2 using electrical discharge machining (EDM) with different tool materials.

HTML
PDF (788 KB)

Abstract

Purpose

This study aims to explore the machinability of ZrB2 using electrical discharge machining (EDM) with different tool materials.

Design/methodology/approach

The workpiece for this study was fabricated through powder metallurgy compaction method. The disc is machined using diamond load grinding to have parallel surfaces, then, 2 mm diameter holes are machined on the disc using EDM spark erosion machine with different tool materials (graphite, aluminium, tantalum, niobium, copper, brass, silver, tungsten and titanium). Roundness, geometry of hole, and diameter of the hole at different diametric planes, surface roughness (SR), material removal rate (MRR), tool wear rate (TWR), taper angle and recast layer (RCL) thickness are measured. The photographic analysis of tools, holes in the top view, bottom view and sectional view. SEM analysis was conducted to study the recast layer. Desirability function analysis was employed to rate the performances of tools.

Findings

A new theory is developed which relates recast layer thickness with melting point and thermal conductivity of the tool materials. Machining of ZrB2 by EDM is feasible; graphite is identified as the best tool. Recast layer thickness of the machined surfaces are indirectly proportional to the product of melting point and thermal conductivity of tool. Ablation behaviour of ceramic workpiece lead additional material losses in the tool.

Originality/value

Extremely high strength and hardness of ZrB2 due to the coexistence of strong covalent and metallic bond make mechanical machining very difficult or even impossible. No machinability studies were conducted previously on ZrB2 using EDM; this work reveals machinability study of ZrB2 with different tool materials.

Details

Multidiscipline Modeling in Materials and Structures, vol. 8 no. 4
Type: Research Article
DOI: https://doi.org/10.1108/15736101211281614
ISSN: 1573-6105

Keywords

  • Ceramic matrix composite
  • Hot pressing
  • Electrical discharge machining
  • Machinability
  • Ceramic machining
  • Desirability functional analysis
  • Electric discharges
  • Ceramics

Access
Only content I have access to
Only Open Access
Year
  • Last 3 months (2)
  • Last 6 months (3)
  • Last 12 months (7)
  • All dates (57)
Content type
  • Article (53)
  • Book part (2)
  • Case study (1)
  • Earlycite article (1)
1 – 10 of 57
Emerald Publishing
  • Opens in new window
  • Opens in new window
  • Opens in new window
  • Opens in new window
© 2021 Emerald Publishing Limited

Services

  • Authors Opens in new window
  • Editors Opens in new window
  • Librarians Opens in new window
  • Researchers Opens in new window
  • Reviewers Opens in new window

About

  • About Emerald Opens in new window
  • Working for Emerald Opens in new window
  • Contact us Opens in new window
  • Publication sitemap

Policies and information

  • Privacy notice
  • Site policies
  • Modern Slavery Act Opens in new window
  • Chair of Trustees governance statement Opens in new window
  • COVID-19 policy Opens in new window
Manage cookies

We’re listening — tell us what you think

  • Something didn’t work…

    Report bugs here

  • All feedback is valuable

    Please share your general feedback

  • Member of Emerald Engage?

    You can join in the discussion by joining the community or logging in here.
    You can also find out more about Emerald Engage.

Join us on our journey

  • Platform update page

    Visit emeraldpublishing.com/platformupdate to discover the latest news and updates

  • Questions & More Information

    Answers to the most commonly asked questions here