Scholarlink

<p>The electric discharge machining process uses spark activity in the presence of dielectric to remove undesired material. However, it is limited by its slow processing rates and poor surface integrity uncontrolled spark energy. The current work evaluates the interaction of cryogenically treated electrodes benefiting from their refined microstructure, and hybrid nanofluid–based dielectrics amplifying the discharge activity. The effects of nanoparticles (graphene (Gr) + silicon carbide (SiC) + alumina (Al<sub>2</sub>O<sub>3</sub>)) to the electrode-workpiece interaction zone being mixed in a surfactant for enhanced surface tension are evaluated on the machining performance measures such as material removal rate (MRR), electrode wear rate (EWR), and microhardness (MH) of SS310 during the EDM process. Statistical methods are employed to quantify the sensitivity of key EDM parametric such as powder concentration (P<sub>C</sub>), spark voltage (S<sub>V</sub>), peak current (I<sub>P</sub>), and pulse on time (P<sub>ON</sub>) on machining performance measures. The results revealed that cryogenically treated (CT) copper (Cu) outperformed the conventional non-cryogenic-treated (NT) electrode with a 24.74% higher MRR and 27.29% better MH and 28.71% reduction in EWR at high energy parametric levels, attributed to improved thermal conductivity from cryogenic treatment. The scanning electron microscopic, statistical, and optimization analyses are performed to understand the physical mechanisms of the process. SEM analysis revealed that CT Cu creates smaller, more uniform craters with fewer defects, while NT Cu forms deeper, irregular craters with increased carbon buildup. The NT Cu electrode, with a composite desirability (d<sub>G</sub>) value of 0.573, performs optimally at P<sub>C</sub> = 4&#xa0;g/L, I<sub>P</sub> = 17.90 A, S<sub>V</sub> = 7.92&#xa0;V, and P<sub>ON</sub> = 130&#xa0;µs, achieving MRR of 24.28 mm<sup>3</sup>/min, MH of 533.83 HV, and EWR of 12.97 mm<sup>3</sup>/min.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Evaluating the interaction of cryogenically treated electrodes with hybrid nanofluid–based dielectrics during electric discharge machining of stainless steel 310

  • 期刊论文

  • 发表日期：

    2025年6月20日

查看全文
  • Muhammad Asad Ali,
  • Muhammad Sana,
  • Sana Ehsan,
  • Mehdi Tlija,
  • Muhammad Umar Farooq,
  • Aqib Mashood Khan

摘要

The electric discharge machining process uses spark activity in the presence of dielectric to remove undesired material. However, it is limited by its slow processing rates and poor surface integrity uncontrolled spark energy. The current work evaluates the interaction of cryogenically treated electrodes benefiting from their refined microstructure, and hybrid nanofluid–based dielectrics amplifying the discharge activity. The effects of nanoparticles (graphene (Gr) + silicon carbide (SiC) + alumina (Al2O3)) to the electrode-workpiece interaction zone being mixed in a surfactant for enhanced surface tension are evaluated on the machining performance measures such as material removal rate (MRR), electrode wear rate (EWR), and microhardness (MH) of SS310 during the EDM process. Statistical methods are employed to quantify the sensitivity of key EDM parametric such as powder concentration (PC), spark voltage (SV), peak current (IP), and pulse on time (PON) on machining performance measures. The results revealed that cryogenically treated (CT) copper (Cu) outperformed the conventional non-cryogenic-treated (NT) electrode with a 24.74% higher MRR and 27.29% better MH and 28.71% reduction in EWR at high energy parametric levels, attributed to improved thermal conductivity from cryogenic treatment. The scanning electron microscopic, statistical, and optimization analyses are performed to understand the physical mechanisms of the process. SEM analysis revealed that CT Cu creates smaller, more uniform craters with fewer defects, while NT Cu forms deeper, irregular craters with increased carbon buildup. The NT Cu electrode, with a composite desirability (dG) value of 0.573, performs optimally at PC = 4 g/L, IP = 17.90 A, SV = 7.92 V, and PON = 130 µs, achieving MRR of 24.28 mm3/min, MH of 533.83 HV, and EWR of 12.97 mm3/min.