Analysis of Machining Characteristics in Additive Mixed Electric Discharge Machining of Nickel-Based Super Alloy Inconel 718

Additive mixed electric discharge machining (AEDM) is a recent innovation for enhancing the capabilities of electrical discharge machining process. The objective of present research work is to study the influence of operating process input parameters on machining characteristics of nickel-based super alloy (Inconel 718) in aluminium AEDM with copper electrode. The effectiveness of AEDM process on Inconel is evaluated in terms of material removal rate (MRR), surface roughness (SR), and wear ratio (WR) using one variable at a time (OVAT) approach. It is found experimentally that particle concentration and size significantly affect machining efficiency. Aluminium powder (325 mesh size) particles of concentration 6 g/l in AEDM produce maximum machining rate, minimum SR, and 4 g/l produces minimum WR within experimental conditions.

[1]  A. Erden,et al.  Role of Impurities in Electric Discharge Machining , 1981 .

[2]  M. L. Jeswani,et al.  Effect of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining , 1981 .

[3]  Gary F. Benedict,et al.  Nontraditional Manufacturing Processes , 1987 .

[4]  Naotake Mohri,et al.  A new process of finish machining on free surface by EDM methods , 1991 .

[5]  Y. Wong,et al.  Near-mirror-finish phenomenon in EDM using powder-mixed dielectric , 1998 .

[6]  Yih-fong Tzeng,et al.  Effects of Powder Characteristics on Electrodischarge Machining Efficiency , 2001 .

[7]  W. Zhao,et al.  The application of research on powder mixed EDM in rough machining , 2002 .

[8]  Stephen T. Newman,et al.  State of the art electrical discharge machining (EDM) , 2003 .

[9]  Sachin Maheshwari,et al.  Some investigations into the electric discharge machining of hardened tool steel using different electrode materials , 2004 .

[10]  Pradeep Kumar,et al.  PARAMETRIC OPTIMIZATION OF POWDER MIXED ELECTRICAL DISCHARGE MACHINING BY RESPONSE SURFACE METHODOLOGY , 2005 .

[11]  Sehijpal Singh,et al.  Application of Taguchi method for optimisation of powder mixed electrical discharge machining , 2005, Int. J. Manuf. Technol. Manag..

[12]  R. K. Bhoi,et al.  Electro-Discharge Machining–A Qualitative Approach , 2006 .

[13]  L. Hwang,et al.  Machining Characteristics and Optimization of Machining Parameters of SKH 57 High-Speed Steel Using Electrical-Discharge Machining Based on Taguchi Method , 2006 .

[14]  Norliana Mohd Abbas,et al.  A review on current research trends in electrical discharge machining (EDM) , 2007 .

[15]  Pradeep Kumar,et al.  Technology and research developments in powder mixed electric discharge machining (PMEDM) , 2007 .

[16]  Anilesh Kumar,et al.  Performance Evaluation of Powder Metallurgy Electrode in Electrical Discharge Machining of AISI D2 Steel Using Taguchi Method , 2008 .

[17]  Yan-cherng Lin,et al.  Machining Performance and Optimizing Machining Parameters of Al2O3–TiC Ceramics Using EDM Based on the Taguchi Method , 2009 .

[18]  P. V. Rao,et al.  Determination of an Optimum Parametric Combination Using a Surface Roughness Prediction Model for EDM of Al2O3/SiCw/TiC Ceramic Composite , 2009 .

[19]  Aloke Dey,et al.  Experimental results and analysis for Electrical Discharge Machining (EDM) of aluminium metal matrix composites with powder-mixed dielectric: Lenth's method , 2010, Int. J. Manuf. Technol. Manag..

[20]  Chitra Sharma,et al.  A Study of Multiobjective Parametric Optimization of Silicon Abrasive Mixed Electrical Discharge Machining of Tool Steel , 2010 .

[21]  Chitra Sharma,et al.  Research Developments in Additives Mixed Electrical Discharge Machining (AEDM): A State of Art Review , 2010 .