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Determination of residual stress distribution in high strength aluminum alloy after EDM

100%

Mehmood S. , Sultan A. , Anjum N. A. , Anwar W. , Butt Z.

2017

tom Vol. 11, no 1

29--35

Thermal energy produced by discrete and random electric sparks in electric discharge machining (EDM) melts surface material. A portion of this molten material is removed and the remaining material resolidified by rapid cooling in a hydrocarbon oil. The effect of repeated heating and cooling of the surface and sub surface material with complex temperature gradients results in residual stresses in machined parts. The aim of this investigation is to determine the distribution of residual stresses in the depth of machined material with respect to discharge current, most important electric parameter during EDM. It is well known that surface finish is dependent on discharge current. Therefore, investigations were carried out for smaller discharge current levels i.e. 3, 6, 9, 12 ampere. Hole-drill strain gauge method is used for the determination of residual stresses in the depth of material. For comparison purposes, residual stresses are also determined for conventionally turned specimens. This study provided quantitative analysis of the residual stresses for various discharge current in EDM which is a key parameter in deciding the service life of material.

3D Optical and Mechanical Roughness Measurements of Complex and Irregular Structures on the Basis of Polypropylene Moldings

88%

Rojewski M. , Nowinka B. , Czyżewski P.

Advances in Science and Technology. Research Journal

2024

tom Vol. 18, no 5

245--257

The most frequently used method for measuring surface roughness is profilographometry. However, with complex and non-homogeneous surfaces, this method may be subject to large errors because of its contact nature and limitations related to the geometry of the measuring head. In this study, the surface topography was examined on polypropylene injection moldings produced using an injection mold with a complex molding cavity surface. The moldings were modified using a Nd:YAG laser, and the obtained structures were examined using two measurement methods, i.e. contact (profilographometry) and optical (3D digital microscopy). Researchers performed a statistical analysis to determine the differences between the measurement results obtained for the two methods. Additionally, the impact of the laser parameters on the modified surface was determined. The obtained results showed significant differences between the values of measurements made using different methods, especially in the case of surfaces that were modified by the laser beam to the greatest extent (laser A parameters). In all cases where a statistically significant difference was found between the measurement results, the mechanical method showed lower roughness values than the optical method, and the average difference between these results was 15%.

Parametric optimization of process parameters for Electric discharge Machining of Tungsten carbide (93% WC and 7%Co)

63%

Sharma R. K.

Production Engineering Archives

2020

tom Vol. 26, Iss. 4

154--161

Nowadays there is a huge demand of High Strength Temperature Resistance (HSTR) alloys such as titanium, carbide, nimonics and ceramics in aerospace, defence and electronics. Among these alloys machining of tungsten carbide alloy is of interest, because of its numerous applications. Complex shapes of tungsten carbide are not generally made by traditional manufacturing process. To machine tungsten carbide with high accuracy, non-traditional machining process like Laser beam machining, Electron beam machining and Electrical discharge machining are a proper choice. In the present paper, the authors have machined Tungsten carbide (93% WC and 7%Co) with copper electrode. The machining is performed on EDM MODEL 500 X 300 ENC with VELVEX EDMVEL-2 as dielectric oil. The 17 experiments are carried out based on RSM (Box-Behnken) method. Further, in order to find the optimum combination grey relational approach is used. The results showed that pulse-on-time of 40µs, pulse-off-time of 2µs and current of 8A are optimum combination for machining of Tungsten carbide (93% WC and 7%Co). Lastly, the confirmation experiment has been conducted.

Machining parameter optimization for EDM machining of Mg–RE–Zn–Zr alloy using multi-objective Passing Vehicle Search algorithm

63%

Parsana S. , Radadia N. , Sheth M. , Sheth N. , Savsani V. , Prasad N. E. , Ramprabhu T.

Archives of Civil and Mechanical Engineering

2018

tom Vol. 18, no. 3

799--817

Mg alloys are known for their specific strength, stiffness, damping capacity, EMI shielding. Particularly, Rare earths added Mg alloys find applications in the gear box casing, transmission housing, engine mount, ribs, frames, instrument panels due to their improved corrosion resistance, pressure tightness, specific strength and creep strength. Reemergence of Mg alloys in the aircraft structural applications demands for advanced machining processes such as EDM to fabricate complex geometry parts. In this study, parametric multi-objective optimization of EDM on Mg–RE–Zn–Zr alloy is carried out using the novel meta-heuristic algorithm – Passing Vehicle Search (PVS). The input parameters considered are pulse-on (Ton), pulse-off (Toff) and peak current (A). Response surface method (RSM) is implemented through the Box–Behnken design to formulate a mathematical model for Material Removal Rate (MRR), Tool Wear Rate (TWR) and Roundness of holes. The accuracy of theoretical model has been established using the confirmation runs. Using the weighted sum method, the multi-objective PVS calculated optimal solutions for different weights to generate 2-D and surface pareto fronts. These pareto fronts were evaluated for performance determination of PVS using novel and established metrics such as spacing, spreading, hypervolume and pure diversity. The values of performance metrics indicate acceptable nature of the graphs and such analysis would facilitate better comparisons of solutions to select algorithms for optimization. Finally, decision making is illustrated with the help of level diagrams to draw up practical inferences for designing production plans and providing the best choice of machining parameters according to their preferences.