Abstract
Inconel 706 is a newly developed aeronautical material that has corrosion resistance along with high mechanical strength. Conventional machining of Inconel 706 results in a poor surface finish and a low-dimensional accuracy. Hence, micro-EDM (electrical discharge machining) is utilized to machine Inconel 706. This work proposes a comparison of micro-EDM characteristics of Inconel 706 between EDM oil and an Al powder mixture. The effects of input parameters on the surface roughness, material removal rate, tool removal rate, and microstructures of the machined surfaces between EDM oil and EDM oil mixed with Al were investigated. It was clarified that micro-EDM with a certain amount of Al powder added to the EDM oil can attain a high MRR and better surface integrity. However, the TWR discharge gap was larger than that in the EDM oil. Furthermore, it was observed that more attachment of the workpiece was adhered to the top surface of the electrode in the EDM oil due to its unstable machining. It was explained that the MRR increases with an increase in the Al concentration and then tends to decline.
Highlights
Nickel-based superalloys have become a promising material in aircraft turbines, nuclear reactors, petrochemical plants, food processing equipment, etc. [1]
The SR and materials removal rate (MRR) of Inconel alloys mainly depends on the input parameters. e diameter of the wire in WEDM was investigated by Sharma et al, who concluded that a smaller diameter wire is advantageous over a larger diameter wire, since it improves productivity and the surface quality of the machined components [11]
All of the above have to do with WEDM, which cannot meet the requirements for machining small holes and special shapes in components of Inconel alloy. erefore, it is necessary to study sinker EDM of Inconel alloy. e sinker EDM is a comprehensive machining technology. e study of Inconel alloys using EDM is critical for meeting ideal industrial requirements. ere are a few studies on PMEDM of Inconel alloys
Summary
Nickel-based superalloys have become a promising material in aircraft turbines, nuclear reactors, petrochemical plants, food processing equipment, etc. [1]. E common methods for cutting Inconel alloys, such as ramping or taper turning and rotary machining, will eliminate the predominant notching of the cutting tools. EDM (electrical discharge machining) has become an effective way to machine Inconel alloys. Research on machining Inconel alloys mainly focuses on WEDM (wire electrical discharge machining). Garg et al proposed the effect of wire materials on the cutting performance of WEDM for machining an Inconel superalloy. An investigation of the machining time and surface roughness in a wire-EDM for Inconel 800 was conducted by Majumder et al It was observed that a Advances in Materials Science and Engineering better surface finish can be machined by a smaller pulse-on time and pulse current [10]. Tiwary et al were involved in an investigation on the effect of dielectrics during microelectro discharge machining of Ti-6Al-4 V [14]. ey determined that the machined profile and topography of the microhole obtained with Cu powder mixed with deionized water were found to be superior compared to those machined with EDM oil or pure deionized water
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