PMEDM process parameter optimization for machining superalloy MONEL 400
MONEL 400, widely used in industries such as high-temperature applications, chemical processing, automotive, and marine sectors, presents significant machining challenges due to its high strength and tendency for work-hardening. This research explores powder-mixed electrical discharge machining (PME...
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| Format: | Article |
| Language: | English |
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IOP Publishing
2025-01-01
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| Series: | Materials Research Express |
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| Online Access: | https://doi.org/10.1088/2053-1591/adb0a4 |
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| author | Abhishek Kumar Manoj Nikam T Jagadeesha Ateekh Ur Rehman Ajay S Bhongade Teli Shivagond |
| author_facet | Abhishek Kumar Manoj Nikam T Jagadeesha Ateekh Ur Rehman Ajay S Bhongade Teli Shivagond |
| author_sort | Abhishek Kumar |
| collection | DOAJ |
| description | MONEL 400, widely used in industries such as high-temperature applications, chemical processing, automotive, and marine sectors, presents significant machining challenges due to its high strength and tendency for work-hardening. This research explores powder-mixed electrical discharge machining (PMEDM), a modern technique incorporating conductive metal powders, specifically graphite and silicon, combined with dielectric fluid to improve machining performance. The study investigates into how to machine MONEL 400 with copper as the cathode, focusing on important process parameters such as powder concentration, peak-current, and pulse on duration. This study also compared impact of PMEDM to conventional EDM, and results demonstrated improvements in material removal rate, tool wear rate, and surface roughness. Graphite powder significantly reduced tool wear, while silicon powder significantly enhanced surface finish. Using Buckingham’s theorem and regression analysis, this study presented semi-empirical models for the rate of material removal and looks at how the powder additives’ dielectric properties have changed to improve performance. The research aims to improve sustainable machining practices while providing environmental benefits. |
| format | Article |
| id | doaj-art-775ffb81accb494f8d69ba22533565bd |
| institution | Kabale University |
| issn | 2053-1591 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | Materials Research Express |
| spelling | doaj-art-775ffb81accb494f8d69ba22533565bd2025-02-11T14:15:14ZengIOP PublishingMaterials Research Express2053-15912025-01-0112202650610.1088/2053-1591/adb0a4PMEDM process parameter optimization for machining superalloy MONEL 400Abhishek Kumar0Manoj Nikam1https://orcid.org/0000-0001-8440-9556T Jagadeesha2https://orcid.org/0000-0003-2072-4391Ateekh Ur Rehman3https://orcid.org/0000-0003-2265-5828Ajay S Bhongade4https://orcid.org/0000-0003-1089-3212Teli Shivagond5Department of Mechanical Engineering, National Institute of Technology , Calicut, Kerala-673601, IndiaDepartment of Creative Technology, School of Design, Shri Vile Parle Kelavani Mandal’s Narsee Monjee Institute of Management Studies (SVKM’s NMIMS), Mumbai-400 056, IndiaDepartment of Mechanical Engineering, National Institute of Technology , Calicut, Kerala-673601, IndiaDepartment of Industrial Engineering, College of Engineering, King Saud University , Riyadh-12372, Saudi ArabiaDepartment of Mechanical Engineering, Bharati Vidyapeeth College of Engineering , Navi Mumbai-400614, IndiaDepartment of Mechanical Engineering, Bharati Vidyapeeth College of Engineering , Navi Mumbai-400614, IndiaMONEL 400, widely used in industries such as high-temperature applications, chemical processing, automotive, and marine sectors, presents significant machining challenges due to its high strength and tendency for work-hardening. This research explores powder-mixed electrical discharge machining (PMEDM), a modern technique incorporating conductive metal powders, specifically graphite and silicon, combined with dielectric fluid to improve machining performance. The study investigates into how to machine MONEL 400 with copper as the cathode, focusing on important process parameters such as powder concentration, peak-current, and pulse on duration. This study also compared impact of PMEDM to conventional EDM, and results demonstrated improvements in material removal rate, tool wear rate, and surface roughness. Graphite powder significantly reduced tool wear, while silicon powder significantly enhanced surface finish. Using Buckingham’s theorem and regression analysis, this study presented semi-empirical models for the rate of material removal and looks at how the powder additives’ dielectric properties have changed to improve performance. The research aims to improve sustainable machining practices while providing environmental benefits.https://doi.org/10.1088/2053-1591/adb0a4PMEDMMONEL 400process parameters optimizationtool wearsustainable machiningmaterial removal rate |
| spellingShingle | Abhishek Kumar Manoj Nikam T Jagadeesha Ateekh Ur Rehman Ajay S Bhongade Teli Shivagond PMEDM process parameter optimization for machining superalloy MONEL 400 Materials Research Express PMEDM MONEL 400 process parameters optimization tool wear sustainable machining material removal rate |
| title | PMEDM process parameter optimization for machining superalloy MONEL 400 |
| title_full | PMEDM process parameter optimization for machining superalloy MONEL 400 |
| title_fullStr | PMEDM process parameter optimization for machining superalloy MONEL 400 |
| title_full_unstemmed | PMEDM process parameter optimization for machining superalloy MONEL 400 |
| title_short | PMEDM process parameter optimization for machining superalloy MONEL 400 |
| title_sort | pmedm process parameter optimization for machining superalloy monel 400 |
| topic | PMEDM MONEL 400 process parameters optimization tool wear sustainable machining material removal rate |
| url | https://doi.org/10.1088/2053-1591/adb0a4 |
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