GENERATION OF EFFUSION HOLES ON ULTRA-HIGH TEMPERATURE ALLOY BY MICRO ELECTRO-DISCHARGE MACHINING PROCESS

Debabrata Dhupal, Debasish Panigrahi, Sweta Rout, Rajesh Kumar Bhuyan, Soumyaranjan Nayak, Pankaj Charan Jena and Sudhansu Ranjan Das
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Debabrata Dhupal: Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, India
Debasish Panigrahi: ��Department of Mechanical Engineering, National Institute of Technology, Rourkela 769008, India
Sweta Rout: ��Department of Mechanical Engineering, National Institute of Technology, Rourkela 769008, India
Rajesh Kumar Bhuyan: ��Biju Patnaik University of Technology, Rourkela 769015, India
Soumyaranjan Nayak: Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, India
Pankaj Charan Jena: Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, India
Sudhansu Ranjan Das: Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, India

Surface Review and Letters (SRL), 2024, vol. 31, issue 02, 1-23

Abstract: Fabrication of surface features like effusion holes on ultra-high temperature (UHT) alloys with micro electro-discharge machining (μ-EDM) is a very convolute strategy. Due to the exceptional mechanical properties and resistance to ease brittle transformation at elevated temperatures, UHT alloys are being widely used in hot sections of aero engines. This research tailored the existing capabilities of μ-EDM setup by employing a copper-tungsten (Cu-W) hybrid tool electrode which has been rarely reported. This research addresses investigations, predictive modeling, and optimization during μ-EDM of UHT alloy, namely Inconel 718. For experimentation, the factors like inter-electrodes gap (IEG), current (I), and pulse on/off time (Ton, Toff) were considered as input variables to analyze the responses like overcut (OC), tool wear rate (TWR), material removal rate (MRR), and diametric alterations in between the top and bottom shape of holes’ feature (DE). The multi-objective desirability-based artificial bee colony optimization (MOABC) projected optimal parametric settings of 5.276 A, 16.389 μs, 1.77 μs, and 50 μm for I, Ton, Toff, and IEG, respectively. These settings provide MRR, TWR, OC, and DE solutions of 0.001479, −0.00038, 0.030239, and 0.047048 mm, respectively. Further, the confirmation test has been performed to validate the optimal solution. The results supported the ideal settings with error values of 0.03177, 1.31578, 0.05863, and 0.04704 for MRR, TWR, OC, and DE, respectively. Distinctive diagnostic tests assessed by several statistical parameters (P, F, R2, AD-P values) confirmed that the accuracy of developed models for prediction of various performance characteristics has high degree of resemblance with experimental results and the adequacy as well as accuracy of models is also demonstrated. Moreover, the surface morphology has also been scrutinized by microscopical observation to perceive the consequences of the electro-discharge phenomenon on both electrodes. Overall, the research comprises experimentation, surface integrity study, and parametric optimization followed by a confirmation test to perform the betterment of the current μ-EDM approach.

Keywords: Cu-W electrode; effusion holes; Inconel 718; μ-EDM; MOABC; surface integrity (search for similar items in EconPapers)
Date: 2024
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DOI: 10.1142/S0218625X2450015X

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