Engineering › Electrical and Electronic Engineering

Advanced Machining and Optimization Techniques

Works Count: 34287

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Description

This cluster of papers represents the advancements and research trends in Electrical Discharge Machining (EDM), including topics such as micromachining, wire EDM, electrochemical machining, optimization of process parameters, surface modification, and the use of hybrid processes. The papers cover a wide range of studies on material removal rate, Taguchi method, and the influence of various factors on EDM performance.

Keywords

Electrical Discharge Machining; Micromachining; Wire EDM; Electrochemical Machining; Optimization; Surface Modification; Taguchi Method; Material Removal Rate; Process Parameters; Hybrid Processes

Surface integrity in material removal processes: Recent advances

2011-01-01

I.S. Jawahir , E. Brinksmeier , Rachid M’Saoubi +5 more

The use of the orthogonal array with grey relational analysis to optimize the electrical discharge machining process with multiple performance characteristics

2002-01-01

Jiang Lin , C.L Lin

Review of Electrochemical and Electrodischarge Machining

2013-01-01

K. P. Rajurkar , Murali Sundaram , Ajay P. Malshe

Electrochemical and electro-discharge machining processes are the two major electro-machining processes with unique capabilities. Electrical Discharge Machining (EDM) and Electrochemical Machining (ECM) offer a better alternative or sometimes the only … Electrochemical and electro-discharge machining processes are the two major electro-machining processes with unique capabilities. Electrical Discharge Machining (EDM) and Electrochemical Machining (ECM) offer a better alternative or sometimes the only alternative in generating accurate 3-D complex shaped macro, micro and nano features and components of difficult–to-machine materials. Technological advances reported in electrochemical and electro discharge machining processes, which reflect the state of the art in academic and industrial research and applications, are briefly reviewed in this paper.

The machinability of inconel 718

1997-01-01

M. Rahman , W.K.H. Seah , T.T. Teo

Hybrid processes in manufacturing

2014-01-01

Bert Lauwers , Fritz Klocke , A. Klink +3 more

Influence of EDM process parameters in deep hole drilling of Inconel 718

2007-05-30

P. Kuppan , A. Rajadurai , Sandeep Narayanan

Advancing EDM through Fundamental Insight into the Process

2005-01-01

Masanori Kunieda , Bert Lauwers , K. P. Rajurkar +1 more

Micro and Nano Machining by Electro-Physical and Chemical Processes

2006-01-01

K. P. Rajurkar , Gideon Levy , Ajay P. Malshe +5 more

Micromachining applications of a high resolution ultrathick photoresist

1995-11-01

Kangsik Lee , N. LaBianca , S. A. Rishton +4 more

This article describes a new negative-tone photoresist, SU-8, for ultrathick layer applications. An aspect ratio of 10:1 has been achieved using near-ultraviolet lithography in a 200-μm-thick layer. The use of … This article describes a new negative-tone photoresist, SU-8, for ultrathick layer applications. An aspect ratio of 10:1 has been achieved using near-ultraviolet lithography in a 200-μm-thick layer. The use of this resist for building tall micromechanical structures by deep silicon reactive-ion etching and electroplating is demonstrated. Using SU-8 stencils, etched depths of ≳200 μm in Si and electroplated 130-μm-thick Au structures with near-vertical sidewalls have been achieved.

Micro-EDM for Three-Dimensional Cavities - Development of Uniform Wear Method -

1998-01-01

Ze Yu , T. Masuzawa , Masahisa Fujino

Fabrication and Machining of Metal Matrix Composites: A Review

2015-03-23

Preetkanwal Singh Bains , Sarabjeet Singh Sidhu , H. S. Payal

Intrinsically smart, metal matrix composites (MMCs) are lightweight and high-performance materials having ever expanding industrial applications. The structural and the functional properties of these materials can be altered as per … Intrinsically smart, metal matrix composites (MMCs) are lightweight and high-performance materials having ever expanding industrial applications. The structural and the functional properties of these materials can be altered as per the industrial demands. The process technologies indulged in fabrication and machining of these materials attract the researchers and industrial community. Hybrid electric discharge machining is a promising and the most reliable nonconventional machining process for MMCs. It exhibits higher competence for machining complex shapes with greater accuracy. This paper presents an up-to-date review of progress and benefits of different routes for fabrication and machining of composites. It reports certain practical analysis and research findings including various issues on fabrication and machining of MMCs. It is concluded that polycrystalline tools and diamond-coated tools are best suitable for various conventional machining operations. High speed, small depth of cut and low feed rate are a key to better finish. In addition, hybrid electrical discharge machining has proved to be an active research area in critical as well as nonconventional machining since last few years. This paper incorporates year-wise research work done in fabrication, conventional machining, nonconventional machining, and hybrid machining of MMCs. Conclusions and future scope are addressed in the last section of the paper.

A review on current research trends in electrical discharge machining (EDM)

2006-11-20

Norliana Mohd Abbas , Darius Gnanaraj Solomon , Md. Fuad Bahari

Some investigations into the electric discharge machining of hardened tool steel using different electrode materials

2004-04-09

Shankar Singh , Sachin Maheshwari , P.C. Pándey

Machinability of nickel-base super alloys: a general review

1998-05-01

Imtiaz Ahmed Choudhury , M.A. El-Baradie

Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide

2001-09-01

Sie Huey Lee , X.P. Li

Wire Electro-Discharge Grinding for Micro-Machining

1985-01-01

T. Masuzawa , Masahisa Fujino , K. Kobayashi +2 more

A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method

2004-06-22

Nihat Tosun , Can Çoğun , Gül Tosun

Theoretical models of the electrical discharge machining process. II. The anode erosion model

1989-11-01

Mukund R. Patel , María A. Barrufet , Philip T. Eubank +1 more

As a second in a series of theoretical models for the electrical discharge machining (EDM) process, an erosion model for the anode material is presented. As with our point heat-source … As a second in a series of theoretical models for the electrical discharge machining (EDM) process, an erosion model for the anode material is presented. As with our point heat-source model in the previous article, the present model also accepts power rather than temperature as the boundary condition at the plasma/anode interface. A constant fraction of the total power supplied to the gap is transferred to the anode. The power supplied is assumed to produce a Gaussian-distributed heat flux on the surface of the anode material. Furthermore, the area upon which the flux is incident is assumed to grow with time. The model is capable of showing, via the determined migrating melt fronts, the rapid melting of the anodic material as well as the subsequent resolidification of the material foation from plasma dynamics modeling could improve substantially our results.

Prediction of compressive strength of concrete by neural networks

2000-08-01

Ni Hong-Guang , Wang Ji-Zong

Parametric optimization of powder mixed electrical discharge machining by response surface methodology

2005-06-24

H.K. Kansal , Sehijpal Singh , Paras Kumar

Electrical discharge machining of titanium alloy (Ti–6Al–4V)

2007-05-25

Ahmet Hasçalık , Ulaş Çaydaş

State of the art in wire electrical discharge machining (WEDM)

2004-06-17

K.H Ho , Stephen T. Newman , Shahin Rahimifard +1 more

Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of Al alloy SiC particle composites

2012-08-23

Rajesh Kumar Bhushan

The application of research on powder mixed EDM in rough machining

2002-10-01

Weice Zhao , Qingyu Meng , Z.L Wang

Review on ultrasonic machining

1998-03-01

T.B. Thoe , D.K. Aspinwall , M. L. H. Wise

Comparison Studies of Electrical Discharge Machining (EDM) Process Model for Low Gap Current

2012-01-03

Azli Yahya , Trias Andromeda , Minhat Ade Erawan +3 more

This paper aims to compare the material removal rate, ν between a Dimensional Analysis (DA) model, an Artificial Neural Network (ANN) model and an experimental result for a low gap … This paper aims to compare the material removal rate, ν between a Dimensional Analysis (DA) model, an Artificial Neural Network (ANN) model and an experimental result for a low gap current of an Electrical Discharge Machining (EDM) process. The data analysis is based on a copper electrode and steel workpiece materials. The DA and ANN model that have been developed and reported earlier by authors are used to compare the material removal of EDM process. The result indicated that the ANN model provides better accuracy towards the experimental results.

Three-Dimensional Micromachining by Machine Tools

1997-01-01

T. Masuzawa , Hans Kurt Tönshoff

State of the art electrical discharge machining (EDM)

2003-09-12

K.H Ho , Stephen T. Newman

Overview of NSGA-II for Optimizing Machining Process Parameters

2011-01-01

Yusliza Yusoff , Mohd. Salihin Ngadiman , Azlan Mohd Zain

This paper presents an overview on NSGA-II optimization techniques of machining process parameters. There are many multi objective optimization (MoGA) techniques involved in machining process parameters optimization including multi-objective genetic … This paper presents an overview on NSGA-II optimization techniques of machining process parameters. There are many multi objective optimization (MoGA) techniques involved in machining process parameters optimization including multi-objective genetic algorithm (MOGA), strength Pareto evolutionary algorithm (SPEA), micro genetic algorithm (Micro-GA), Pareto-archived evolution strategy (PAES), etc. This paper reviews the application of non dominated sorting genetic algorithm II (NSGA-II), classified as one of MoGA techniques, for optimizing process parameters in various machining operations. NSGA-II is a well known, fast sorting and elite multi objective genetic algorithm. Process parameters such as cutting speed, feed rate, rotational speed etc. are the considerable conditions in order to optimize the machining operations in minimizing or maximizing the machining performances. Unlike the single objective optimization technique, NSGA-II simultaneously optimizes each objective without being dominated by any other solution.

Machining of non-conducting materials using electrochemical discharge phenomenon—an overview

2005-02-15

Rolf Wüthrich , Valia Fascio

Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model

1989-11-01

D. DiBitonto , Philip T. Eubank , Mukund R. Patel +1 more

A simple cathode erosion model for the electrical discharge machining (EDM) process is presented. This point heat-source model differs from previous conduction models in that it accepts power rather than … A simple cathode erosion model for the electrical discharge machining (EDM) process is presented. This point heat-source model differs from previous conduction models in that it accepts power rather than temperature as the boundary condition at the plasma/cathode interface. Optimum pulse times are predicted to within an average of 16% over a two-decade range after the model is tuned to a single experimental point. A constant fraction of the total power supplied to the gap is transferred to the cathode over a wide range of currents. A universal, dimensionless model is then presented which identifies the key parameters of optimum pulse time factor (g) and erodibility (j) in terms of the thermophysical properties of the cathode material. Compton’s original energy balance for gas discharges is amended for EDM conditions. Here it is believed that the high density of the liquid dielectric causes plasmas of higher energy intensity and pressure than those for gas discharges. These differences of macroscopic dielectric properties affect the microscopic mechanisms for energy transfer at the cathode. In the very short time frames of EDM, our amended model uses the photoelectric effect rather than positive-ion bombardment as the dominant source of energy supplied to the cathode surface.

State of the Art of Micromachining

2000-01-01

T. Masuzawa

Modelling the machining parameters of wire electrical discharge machining of Inconel 601 using RSM

2005-06-14

M.S. Hewidy , T. A. El-Taweel , M.F. El-Safty

Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method

2006-08-16

S.S. Mahapatra , Amar Patnaik

New Developments in Electro-Chemical Machining

1999-01-01

K. P. Rajurkar , Di Zhu , J.A. McGeough +2 more

Surface modification by electrical discharge machining: A review

2008-10-15

Sanjeev Kumar , Rupinder Singh , T.P. Singh +1 more

Effects of Powder Characteristics on Electrodischarge Machining Efficiency

2001-04-20

Y.-F. Tzeng , Chiou‐Yng Lee

Turbomachinery component manufacture by application of electrochemical, electro-physical and photonic processes

2014-01-01

Fritz Klocke , A. Klink , D. Veselovac +6 more

Optimisation of the EDM Process Based on the Orthogonal Array with Fuzzy Logic and Grey Relational Analysis Method

2002-02-26

C.L. Lin , Jiang Lin , Taewoo Ko

Relationship between EDM parameters and surface crack formation

2003-08-08

H.T. Lee , Tzu-Yao Tai

Modeling And Optimizing of Different Quality Characteristics In Electrical Discharge Drilling Of Titanium Alloy (Grade-5) Sheet

2019-01-01

Ankit Jain , Arun Kumar Pandey

Modelling and optimization of different quality characteristics in electric discharge drilling of titanium alloy sheet

2019-12-30

Ankit Jain , Ashwani Kumar Yadav , Yogesh Shrivastava

Surface integrity in metal machining - Part I: Fundamentals of surface characteristics and formation mechanisms

2020-12-30

Zhirong Liao , Andrea la Monaca , James W. Murray +5 more

The surface integrity of machined metal components is critical to their in-service functionality, longevity and overall performance. Surface defects induced by machining operations vary from the nano to macro scale, … The surface integrity of machined metal components is critical to their in-service functionality, longevity and overall performance. Surface defects induced by machining operations vary from the nano to macro scale, which cause microstructural, mechanical and chemical effects. Hence, they require advanced evaluation and post processing techniques. While surface integrity varies significantly across the range of machining processes, this paper explores the state-of-the-art of surface integrity research with an emphasis on their governing mechanisms and emerging evaluation approaches. In this review, removal mechanisms are grouped by their primary energy transfer mechanisms; mechanical, thermal and chemical based. Accordingly, the resultant multi-scale phenomena associated with metal machining are analyzed. The contribution of these material removal mechanisms to the workpiece surfaces/subsurface characteristics is reviewed. Post-processing options for the mitigation of induced surface defects are also discussed.

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Experimental investigations and optimization of surface roughness in turning of en 36 alloy steel using response surface methodology and genetic algorithm

2021-01-01

Vishwanath Panwar , Dilip Kumar Sharma , K.V. Pradeep Kumar +2 more

Micro Engineering

2003-01-01

Leo Alting , F. Kimura , Hans Nørgaard Hansen +1 more

Electrochemical Micromachining

2000-07-07

Rolf Schuster , Viola Kirchner , P. Allongue +1 more

The application of ultrashort voltage pulses between a tool electrode and a workpiece in an electrochemical environment allows the three-dimensional machining of conducting materials with submicrometer precision. The principle is … The application of ultrashort voltage pulses between a tool electrode and a workpiece in an electrochemical environment allows the three-dimensional machining of conducting materials with submicrometer precision. The principle is based on the finite time constant for double-layer charging, which varies linearly with the local separation between the electrodes. During nanosecond pulses, the electrochemical reactions are confined to electrode regions in close proximity. This technique was used for local etching of copper and silicon as well as for local copper deposition.

Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloys

2025-06-24

Kamal Kumar | INTERANTIONAL JOURNAL OF SCIENTIFIC RESEARCH IN ENGINEERING AND MANAGEMENT

wire electrical discharge machining (wire EDM) is broadly hired for precision machining of tough-to-cut substances together with titanium alloys, which find widespread use in aerospace, biomedical, and chemical processing industries, … wire electrical discharge machining (wire EDM) is broadly hired for precision machining of tough-to-cut substances together with titanium alloys, which find widespread use in aerospace, biomedical, and chemical processing industries, floor integrity, in particular surface roughness, plays a critical role in the overall performance and sturdiness of additives made from titanium alloys. This examine systematically investigates the have an impact on of key twine EDM parameters—spark modern-day, pulse-on time, pulse-off time, twine tension, and flushing stress—on the ensuing surface roughness of Ti-6Al-4V specimens. A full-factorial experimental layout became employed to isolate the effects of character parameters and their interactions. floor roughness measurements (Ra) have been received the use of a touch profilometer, and statistical evaluation together with analysis of variance (ANOVA) was performed to discover the maximum substantial individuals to surface end. The outcomes reveal that better spark modern-day and longer pulse-on instances increase surface roughness, whereas optimized pulse-off instances and greater flushing pressure make a contribution to smoother surfaces by using enhancing debris evacuation. wire anxiety exhibited a slight impact, mostly thru its impact on wire stability and spark gap consistency. A predictive regression version with R² = 0.92 changed into advanced for Ra as a function of the method parameters, enabling practitioners to choose parameter units that yield goal surface fine. This work offers actionable recommendations for optimizing twine EDM of titanium alloys to obtain preferred surface integrity even as preserving machining efficiency. Key Words: Wire EDM, surface roughness, Ti-6Al-4V, process parameters, statistical modelling

Comparative analysis of workpiece polarity effects on single-pulse discharge characteristics and crater morphology in electrical arc machining of titanium alloy

2025-06-24

Jianqing Han , Yongqiang Zhou , Zhen Li +3 more | The International Journal of Advanced Manufacturing Technology

Comparative study of supervised learning algorithm to predict cutting force and surface roughness during laser assisted turning of novel AA7178/nTiO2 nanocomposite

2025-06-24

Nikhil Bharat , P. S. C. Bose , Vijay Kumar +1 more | Optics & Laser Technology

Machining parameters optimization for ECAP processed aluminum using grey-fuzzy approach

2025-06-24

S. Surendarnath , C. Ahilan , T. Ramachandran +1 more | International Journal on Interactive Design and Manufacturing (IJIDeM)

Effect of cutting conditions, electrode profiles, and corrosion behavior in electrical discharge machining of LG-2 leaded gunmetal

2025-06-23

Pradeep Kumar J , N. Sivakumar , K Arvind | Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering

Recent applications of heavy-duty gunmetal mechanical elements demand superior quality oil holes for extended service life and significant enhancement in functional aspects. In this work, through-holes of 10 mm diameter … Recent applications of heavy-duty gunmetal mechanical elements demand superior quality oil holes for extended service life and significant enhancement in functional aspects. In this work, through-holes of 10 mm diameter are machined by an electrical discharge machining process in LG-2 gunmetal blocks based on Taguchi L9 orthogonal array. The selected input factors are spark-on time, current, and gap voltage. The multi-criteria optimization technique Taguchi-gray relational analysis is used for optimizing the input factors for machining characteristic responses such as material removal rate, electrode wear rate, surface roughness, and form accuracy characteristics of holes such as circularity, cylindricity, radial overcut, and taper rate. The optimum cutting condition identified is the current of 30 A, gap voltage of 25 V, and spark-on time of 90 µs. Experiments carried out using the optimum cutting conditions with various copper electrode profiles such as cylindrical, conical, tapered, stepped, D-shaped, and curved electrodes reveal that the conical electrode profile is best suited for achieving the required machining and form accuracy characteristics. A comparison of the hole surface characteristics of the three holes machined using conventional drilling, traditional cylindrical electrode, and the conical electrode using salt spray corrosion test and scanning electron microscope reveals the hole machined using a conical electrode profile has minimum surface undulations resulting in better corrosion resistance.

Three-Dimensional Multiphysics Simulation of Gas-Assisted Electrochemical Jet Machining for Hole Inner Surfaces

2025-06-23

Weidong Liu , Haoyang Dong , Yonghua Zhao | Journal of The Electrochemical Society

Abstract Deep-small holes with microstructured inner surfaces have wide applications owing to their exceptional heat transfer performance. Nevertheless, machining the internal features in deep-small holes presents significant challenges. Recently, a … Abstract Deep-small holes with microstructured inner surfaces have wide applications owing to their exceptional heat transfer performance. Nevertheless, machining the internal features in deep-small holes presents significant challenges. Recently, a gas-assisted electrochemical jet machining (EJM) method has been developed for microstructuring hole inner surfaces. However, owing to the complex physical interactions and the invisible in-hole processing environment, the experimentally driven process design remains difficult and time-consuming. In this study, a three-dimensional (3D) multiphysics model was established to numerically investigate the machining mechanism of this novel EJM process and facilitate simulation-based process design. Experiments were conducted in parallel for simulation validation. The interplay between the gas-electrolyte flow field, electric field, and material removal pattern during the machining of hole inner surfaces was analyzed, revealing distinct process characteristics compared to conventional planar surface machining. The influence of key process parameters, including the gas assistance velocity and machining gap, on the underlying physics and machining results was investigated. The results demonstrated the critical role of gas assistance in process control and established the applicability of this novel EJM method for holes of varying diameters. Complex features were successfully machined on hole inner surfaces using the developed gas-assisted EJM process with optimized parameters.

Selective surface area modification of Al-7075 using micro-nano-sized PM green compact in EDC

2025-06-23

Bhargab Madhab Barua , Maneswar Rahang | Materials and Manufacturing Processes

Investigating the Fixed and Moveable Partial Insulation on the Cathode in Electrochemical Machining

2025-06-23

Rupinder Singh , Gurwinder Singh , Arun Dutt Sharma +1 more | Journal of The Institution of Engineers (India) Series C

An online compensation method for the trajectory error of robotic milling using extreme learning machine

2025-06-23

Huang Zhang , Qi Qi , Wenlei Xiao +1 more | International Journal of Computer Integrated Manufacturing

Nano-graphene-mixed rice bran oil: a green substitute for conventional dielectric in EDM

2025-06-21

Kashif Ishfaq , Muhammad Asad , Syed Farhan Raza +3 more | Journal of the Brazilian Society of Mechanical Sciences and Engineering

Experimental Investigation of Al2O3 Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling

2025-06-21

Sharad Yadav , Deepak Agarwal , Anuj Kumar Sharma +3 more | Micromachines

This paper investigates the use of Al2O3 nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder … This paper investigates the use of Al2O3 nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, MRR, depth, and width. A two-stage nested ANOVA is employed to understand the effect of powder concentration within different capacitance levels. The results show that the powder concentration significantly influences the system’s performance in conjunction with the capacitance. At low (100 pF) and high (1000 pF) capacitance, the addition of Al2O3 nano-powder increases the MRR, depth, and width but decreases TWR up to a concentration of 1.0 g/L. A desirability function analysis (DFA) tool identified the best overall performance from 14 experiments, revealing that 100 pF and 1 g/L yield the optimal outcomes.

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

2025-06-20

Muhammad Asad Ali , Muhammad Sana , Sana Ehsan +3 more | The International Journal of Advanced Manufacturing Technology

Effect of Cryotherapy on Cyclic Fatigue of an Electrodischarge-machined NiTi File: A Finite Element Analysis

2025-06-20

Divyameena Bommiah , Ganesh Bharathi D , Y. Kalyan Chakravarthy +3 more | World Journal of Dentistry

Optimization of turning nose radius for Haynes 230: A hybrid RSM and deep learning approach

2025-06-20

Ranganath KJ , H. Shivananda Nayaka | Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering

Haynes 230 is a nickel-based superalloy recognized for its strength and high-temperature performance, making it vital in aerospace, automotive, and energy sectors. However, its hardness and low thermal conductivity pose … Haynes 230 is a nickel-based superalloy recognized for its strength and high-temperature performance, making it vital in aerospace, automotive, and energy sectors. However, its hardness and low thermal conductivity pose machining challenges. This research investigates the impact of nose radius (NR) on the machinability of Haynes 230 during turning, focusing on material removal rate (MRR) and surface quality to find the optimal nose radius for both. The study uses response surface methodology (RSM) with an orthogonal array for experiments, creating quadratic models for surface roughness and MRR. Optimal parameters are validated through a multilayer perceptron (MLP) deep learning model, showing a mean absolute error of 0.37 and mean squared error of 0.26 for regression. The classification achieved a training accuracy of 94.44% and a testing accuracy of 90%, ensuring reliability. The findings indicate that larger nose radii improve the material removal rate (MRR), while smaller nose radii improve the machining surface quality. This optimized compromise aligns with Industry 5.0, where AI-driven smart manufacturing enhances productivity and quality. Deep learning integration ensures accuracy, enabling efficient machining of high-performance materials like Haynes 230.

Implementation of Taguchi approach on the aluminum alloy 2219 metal matrix composites to improve the quality of the drilling process

2025-06-20

Mahadev Madgule , Ajay D. Pingale , Anil S. Katarkar +2 more | Concurrent Engineering

Aluminum alloy 2219 is commonly used in the aerospace and automobile industries due to its favorable properties of low density, high strength, and good performance at cryogenic temperatures. To improve … Aluminum alloy 2219 is commonly used in the aerospace and automobile industries due to its favorable properties of low density, high strength, and good performance at cryogenic temperatures. To improve the mechanical and thermal properties of Al 2219, three reinforcements were added in preparation for the hybrid metal matrix composite (HMMC) such as silicon carbide (SiC), molybdenum disulfide (MoS 2 ), and graphite (Gr). Drilling is a significant manufacturing process, and the investigation of drilling parameters indicates the quality of the drilling process in terms of tool life, hole quality, and energy consumption. In this research work, drilling parameters such as thrust force, torque, and burr were evaluated. Taguchi method is implemented to design an experiment with an L9 orthogonal array. The experiment was conducted with coated carbide and uncoated carbide drill tools. Coated carbide was used because it improves oxidation resistance and reduces friction. The specimen prepared with Al 2219 + 15%SiC + 5%Gr produced the maximum thrust force, torque, and burr when drilled with a coated carbide drill tool compared to other specimens. Feed rate was the main parameter that influenced thrust force and torque. The maximum burr height was produced by the coated carbide drill tool compared to the uncoated carbide drill tool. The metal matrix composite specimen is prepared with a novel combination of reinforcement and matrix materials such as aluminum alloy 2219, Silicon carbide (SiC), and Molybdenum disulfide (MoS 2 ).

Effects of ultrasonic vibration on the machining mechanism of internal cylindrical ultrasonic-assisted electrochemical hybridized grinding of bearing ring: Experimental study

2025-06-19

Xiaosan Ma , Feng Jiao , Fan Chen +4 more | Journal of Manufacturing Processes

Three-Stage Optimization of Surface Finish in WEDM of D2 Tool Steel via Taguchi Design and ANOVA Analysis

2025-06-19

Thanh Tan Nguyen , Bui Phuoc Phi , Van Tron Tran +2 more | Metals

Wire electrical discharge machining (WEDM) is a standard micro-manufacturing technology. In WEDM, surface roughness (SR), deviation dimension (DD), and machining time (MT) are critical requirements that impact machining quality and … Wire electrical discharge machining (WEDM) is a standard micro-manufacturing technology. In WEDM, surface roughness (SR), deviation dimension (DD), and machining time (MT) are critical requirements that impact machining quality and are affected by various input parameters. The workpiece often performs multiple machining steps (roughing, semi-finishing, and finishing) to achieve high accuracy. Each machining step directly affects the accuracy and machining time, and the preceding machining step influences the subsequent machining step parameters. Many input control parameters regulate WEDM’s performance. Thus, optimizing process control parameters at each step is essential to achieve optimal results. This study investigates the influence of input parameters, including pulse on time (Ton), pulse off time (Toff), and servo voltage (SV), on SR, DD, and MT when machining AISI D2 mold steel through rough, semi-finish, and finish cutting. Taguchi and Analysis of Variance (ANOVA) are applied to analyze and optimize this WEDM process. The results display that the optimal surface roughness values for rough, semi-finish, and finish-cut stages are 2.03 µm, 1.77 µm, and 0.57 µm, corresponding to the parameter set of Ton = 6 μs, Toff = 10 μs, and SV = 30 V; Ton = 3 μs, Toff = 15 μs, and SV = 60 V; and Ton = 21 μs, Toff = 45 μs, and SV = 60 V, respectively. In addition, in the finish-cut stage, the parameters for optimal DD of 0.001 mm (0.04%) are Ton = 3 μs, Toff = 15 μs, and SV = 40 V. In contrast, those values for optimal MT of 218 s are Ton = 3 μs, Toff = 30 μs, and SV = 40 V. All optimal input values are confirmed by the manufacturing mold and die parts.

Study of hole sucking on debris evacuation and processing efficiency in EDM of integral shrouded blisks

2025-06-18

Huiliang Wei , Feng Wang , Jing Zhou +2 more | The International Journal of Advanced Manufacturing Technology

Investigation on vacuum-assisted electrochemical drilling of deep-small hole

2025-06-17

Xuanning Wang , Xiaolei Chen , Zhisen Ye +1 more | The International Journal of Advanced Manufacturing Technology

Investigation of Machining Characteristics and Optimization of WEDM Parameters for Spark Plasma Sintered ZrB<sub>2</sub>-B<sub>4</sub>C Ceramic Composite Utilizing RSM, NSGA II, and TOPSIS

2025-06-17

S. Mandal , Shirshendu Chakraborti , Partha Pratim Dey | Engineering Research Express

Abstract A ZrB 2 -B 4 C (75 wt% - 25 wt%) composite ceramic was fabricated using a Spark Plasma Sintering Furnace (SPS) at a temperature of 2000°C. The electrical … Abstract A ZrB 2 -B 4 C (75 wt% - 25 wt%) composite ceramic was fabricated using a Spark Plasma Sintering Furnace (SPS) at a temperature of 2000°C. The electrical conductivity achieved was 1.5×10 5 S/m. The machining performance of the composite was evaluated for the Wire Electrical Discharge Machining (WEDM) process. A central composite design (CCD) was employed to systematically examine the effects of key machining parameters, including pulse on-time (T on ), pulse off-time (T off ), pulse peak current (Ip), dielectric fluid pressure (WP), and servo feed (SF), on machining speed and kerf width. Regression models were developed to establish quantitative relationships between the input parameters and output responses, allowing for precise predictions of WEDM performance. The ANOVA results indicate that all machining parameters significantly influenced machining speed and kerf width, with WP, SF, Ip, and Toff notably affecting machining speed, while Ip, Ton, and SF impacted kerf width. The micrograph of the machined surface reveals a white, re-solidified layer containing numerous craters and protrusions. The machining parameters were optimized by hybrid optimization technique non-dominated sorting genetic algorithm (NSGA-II), and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS), identified the optimal parameter set as Ton = 126 µs, Toff = 60 µs, Ip = 130 A, WP = 9.00 kg/cm², and SF = 2075 mm/min for equal weightage (50%) of both responses.

Optimization of WEDM of a novel Al-MMC using an integrated MCDM approach

2025-06-17

Gaurav Sapkota , Ranjan Kumar Ghadai , Soham Das +2 more | Multidiscipline Modeling in Materials and Structures

Purpose Nowadays, machinability studies of novel aluminium metal matrix composites (Al-MMCs) have become crucial to ensure their applications in automobile, aerospace, marine, packaging, railways, construction and sports industries. Among various … Purpose Nowadays, machinability studies of novel aluminium metal matrix composites (Al-MMCs) have become crucial to ensure their applications in automobile, aerospace, marine, packaging, railways, construction and sports industries. Among various non-traditional machining processes, wire electrical discharge machining (WEDM) has been gaining immense importance among the researchers as a viable option for machining of those Al-MMCs. During the WEDM operation, identification of the optimal combination of its various input parameters is deemed to be crucial for having enhanced efficiency and cut quality. The purpose of this paper is to optimize WEDM operation of a novel hybrid Al-MMC using an integrated approach, fusing together CRiteria Importance Through Intercriteria Correlation (CRITIC) and Mixed Aggregation by COmprehensive Normalization Technique (MACONT). Design/methodology/approach In this paper, a novel Al-MMC is developed using Al 6063 as the base material, and 5% SiC (silicon carbide) and 2.5% CeO2 (cerium oxide) as the reinforcements. It has a fine grain structure with reinforcements trapped around the grain boundaries resulting in higher hardness, better corrosion resistance and adequate strength properties. The developed Al-MMC is machined using a WEDM process based on a Box-Behnken design plan for cutting slits from the bulk. During the WEDM process, peak current (Ip), pulse-on time (Ton) and pulse-off time (Toff) are treated as the input parameters, while material removal rate (MRR), surface roughness (SR) and kerf width (KW) are the responses. Findings Application of the CRITIC method helps in determining the weight of each of the responses considering the information content and randomness of the experimental data. On the other hand, the conducted experiments are ranked employing the MACONT method, developed combining three normalization procedures and two aggregation operators. It is noticed that a compromise solution of Ip = 6 A, Ton = 30 µs and Toff = 10 µs would simultaneously maximize MRR, and minimize both SR and KW values. Originality/value Keeping in mind the immense potential of hybrid composites having more than one reinforcement in enhancing mechanical, tribological and corrosion resistance properties, in this paper, a novel Al-MMC is prepared containing CeO2 (a rare earth element) as one of the reinforcements. It is machined using the WEDM process and later optimized employing a robust integrated multi-criteria decision making tool.

Enhancement of EDM performance for NiTi, NiCu, and BeCu alloys using a multi-criteria approach based on utility function

2025-06-16

Vijaykumar S. Jatti , Vijayan Singarajan , A. Saiyathibrahim +3 more | Metal Working and Material Science

Introduction: Machining hard materials and shape memory alloys (SMAs), such as NiTi, NiCu, and BeCu, using conventional techniques is challenging due to excessive tool wear and poor surface finish. Non-conventional … Introduction: Machining hard materials and shape memory alloys (SMAs), such as NiTi, NiCu, and BeCu, using conventional techniques is challenging due to excessive tool wear and poor surface finish. Non-conventional machining methods, particularly electrical discharge machining (EDM), offer improved precision and surface quality. However, the effectiveness of EDM is contingent upon the optimization of process parameters. The purpose of this study is to optimize EDM parameters to enhance the machining performance of SMAs by considering factors such as pulse-on time, pulse-off time, discharge current, gap voltage, and workpiece electrical conductivity. Methods. In this study, the Taguchi experimental design approach was employed to analyze the influence of key process parameters on the material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR). Analysis of variance (ANOVA) was then applied to identify the most statistically significant factors affecting machining performance. A multi-objective optimization method, based on utility theory, was utilized to determine the optimal EDM settings that balance MRR, SR, and TWR. The results were validated through experimental trials. Results and Discussion. The experimental results indicated that Trial 15 achieved the highest MRR of 9.076 mm³/min, while Trial 1 produced the lowest SR of 2.238 µm. The minimum TWR of 0.041 mm³/min was observed in Trial 10, which contributes to increased tool lifespan. ANOVA revealed that gap voltage was the most influential factor, accounting for 85.98% of the variation in machining performance, followed by discharge current (4.76%) and pulse-off time (2.59%). The multi-objective optimization process successfully identified parameter configurations that optimize MRR while minimizing SR and TWR. The prediction model developed in this study demonstrated high accuracy, with an R² value of 93.3% and an adjusted R² of 89.7%. Validation experiments confirmed the effectiveness of the optimized parameters, resulting in an average MRR of 8.852 mm³/min, SR of 2.818 µm, and TWR of 0.148 mm³/min. The findings presented herein confirm that careful optimization of EDM parameters significantly enhances the machining performance of SMAs, considerably improving machining efficiency and tool longevity.

Study on deep micro hole machining characteristics of magnetic field assisted micro electrical discharge machining with ultrasonic vibration of workpiece

2025-06-16

Peng Yu , Sijun Dong , Yongcheng Gao +6 more | The International Journal of Advanced Manufacturing Technology

Residual stress and its modification strategies in the surface/sub-surface layer of components machined by electrical discharge machining: a review

2025-06-16

Xiaoming Duan , Krishna Kumar Saxena , Jun Wang +5 more | The International Journal of Advanced Manufacturing Technology

Effect of cryogenic treatment on different electrodes to enhance electrochemical machining of WAAM-fabricated SS316L steel

2025-06-16

S. Arumugam , Vijayaragavan Elumalai , Lakshmanan Thangavelu +1 more | Multiscale and Multidisciplinary Modeling Experiments and Design

Energy-efficient cutting path planning for wire electrical discharge machining (WEDM) of Cr12 steel based on energy benchmarking

2025-06-16

Luoke Hu , Jun Zheng , Qiang Zuo +3 more | Machining Science and Technology

Changes in the Surface Area and Volume of Hyflex EDM Instruments after Multiple Uses

2025-06-15

Neslihan Büşra Keskin , Taha Özyürek , Zeliha Uğur Aydın +4 more | Acta Stomatologica Croatica

Effect of discharge parameters on surface integrity and microstructure in electro discharge layering of Ni–Cr composite coating on AA2024 aluminium alloy

2025-06-14

C. V. Asokan , U. Elaiyarasan , Malinee Sriariyanun +2 more | Discover Materials

High speed short electric arc deep hole drilling experimental study based on tube electrode

2025-06-13

Guoyu Hu , Fei Fu , Shengsheng Zhang +3 more | The International Journal of Advanced Manufacturing Technology

A critical insight into the use of EDM for machining advanced ceramic composites – a review

2025-06-13

L. Selvarajan , Bhanu Prakash , T. Niranjan +3 more | Machining Science and Technology

Machine Learning-based Classification of Acoustic Emission Signals in SiC Cathode Ultrasonic Machining Process

2025-06-13

Minkeon Lee , Iljoo Jeong , Ji-Yong Chae | Journal of the Korean Society for Precision Engineering

Monopulse recognition-based interelectrode state detection for self-adjustable micro-EDM servo control

2025-06-13

Peiyao Cao , Tong Hao , Yong Li +2 more | The International Journal of Advanced Manufacturing Technology

Effect of Process Parameters on Material Removal Rate in PMEDM

2025-06-12

Nguyễn Thị Thu Hà | International Journal of Scientific Research in Science and Technology

The use of powder mixed electrical discharge machining helps overcome this drawback and increases the efficiency of the machining process. This study focused on the machining of SKD61, SKD11, and … The use of powder mixed electrical discharge machining helps overcome this drawback and increases the efficiency of the machining process. This study focused on the machining of SKD61, SKD11, and SKT4 die steels using titanium powder. Taguchi methods and analysis of variance were employed to identify the main parameters that affect the material removal rate (MRR). The other process parameters considered were the electrode material, workpiece material, electrode polarity, pulse-on time, pulse-off time, electric current, and titanium powder concentration. The results indicated that electric current, electrode material, and powder concentration were the most significant parameters that influenced the MRR. A powder concentration of 20 g/l increased the MRR by 42.1%, as compared with no-powder machining.

Modeling and optimization of micro-EDM process parameters for Kevlar–carbon interlayer composite using artificial neural network and RSM-based Box–Behnken design

2025-06-12

Hrishikesh Dutta , Satish Chaurasia , Dhanjit Das +1 more | Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering

This study is an attempt to assess the micro-electrical discharge machining behavior of Kevlar–carbon hybrid composites using Box–Behnken design (BBD)-based regression analysis coupled with grey-relational analysis (GRA), and artificial neural … This study is an attempt to assess the micro-electrical discharge machining behavior of Kevlar–carbon hybrid composites using Box–Behnken design (BBD)-based regression analysis coupled with grey-relational analysis (GRA), and artificial neural network (ANN) modeling. Seventeen experimental trials were produced from the BBD, inclusive of repetitions. The variation of machining time (MT) and dimensional deviation (DD) was studied with respect to pulse on time (T on ), voltage (V), and tool rotation (TR). The analysis of variance (ANOVA) was carried out to develop the regression model for each output response. A multilayer feed-forward neural network was employed in the ANN modeling, comprising four neurons in the input layer, 10 neurons in the hidden layer, and two neurons in the output layer. The regression models for MT and DD, derived from ANOVA, aligned effectively with the experimental data. The maximum error values for the regression models of MT and DD are 0.0207 and 0.04483, respectively. T on and TR were the most critical parameters for MT and DD, as seen by their greater F-values (89.68 and 38.02). Controlling these factors precisely and accurately will optimize machining performance. The best input parameters for minimum MT and DD from the GRA are: T on - 30 µs, V - 220 V, and TR - 300 rpm. At ideal input factor levels, MT and DD values from GRA were 800 s and 69 µm, respectively. Experimental grey-relational grade (GR Grade ) was 0.898974, around 4.95% different than predicted (0.85656). The ANN model predicted MT and DD values close to the experimental values. The greatest ANN prediction errors were 5.68% for MT and 9.22% for DD. The ANN model is adequate because the correlation coefficient ( R = 0.99411) is near 1. This study suggests hybrid composite manufacturing industries apply multiresponse optimization with MT and DD.

APLICAÇÃO DE NANOTECNOLOGIA NA REDUÇÃO DE DESGASTE EM EQUIPAMENTOS INDUSTRIAIS

2025-06-12

Estela de Oliveira Lima , Raúl A. Martins , Igor Pınheıro de Araújo Costa +5 more | Revista fisio&terapia.

ABSTRACT Industrial maintenance plays a crucial role in ensuring the efficiency and longevity of productive assets in industries. With the advancement of technologies and the growing demand for more effective … ABSTRACT Industrial maintenance plays a crucial role in ensuring the efficiency and longevity of productive assets in industries. With the advancement of technologies and the growing demand for more effective and sustainable solutions, nanotechnology has emerged as a potential ally in optimizing maintenance strategies. However, while nanotechnology has been widely studied and applied in various industrial fields, its implementation in equipment maintenance remains a relatively new and underexplored subject, which raises the following question: what are the real possibilities of applying nanotechnology to improve industrial maintenance? This research problem aims to understand the impact of nanotechnology on maintenance processes, its benefits, and the challenges associated with its adoption. The main objective of this study is to analyze the applications of nanotechnology in industrial maintenance, with a focus on emerging technologies that can transform maintenance processes and increase equipment lifespan. The research seeks to identify the main nanotechnological solutions that are already being used, evaluate their effects on operational and technical results, and investigate the barriers to their implementation, with emphasis on applications such as nanoparticle-based lubricants, protective coatings, predictive monitoring sensors, and materials with self-sufficiency properties. To achieve these objectives, the methodology adopted was a qualitative and exploratory approach. The research involved a comprehensive literature review of scientific articles, dissertations, theses, and technical reports, allowing the identification of the latest trends and advancements in the areas of nanotechnology applied to maintenance. Data collection also included semi-structured interviews with maintenance engineering specialists to capture practical insights and challenges faced by companies already implementing nanotechnology in their operations. The qualitative analysis of the collected data aims to provide an in-depth understanding of the contributions of nanotechnology to industrial maintenance and offer recommendations on how companies can effectively adopt these innovations. Keywords: Industry 4.0; Maintenance; Efficiency; Nanotechnology.

Engenharia reversa e manufatura aditiva aplicada em uma conexão de água

2025-06-12

Gustavo de Oliveira Lemos , Lucas Nascimento Rodrigues , Guilherme Ribeiro Melo | DELOS Desarrollo Local Sostenible

A engenharia reversa é importante, para entender um produto, assim, analisar seus componentes de forma individual. Em conjunto com o uso da manufatura aditiva, pode-se otimizar os processos, principalmente se … A engenharia reversa é importante, para entender um produto, assim, analisar seus componentes de forma individual. Em conjunto com o uso da manufatura aditiva, pode-se otimizar os processos, principalmente se algum componente parou de ser fabricado ou é necessário comprá-lo no exterior. Isso facilita para os fornecedores fabricar determinada peça, e com potencial de redução de custo, e economizando tempo. O presente projeto tem como objetivo utilizar como exemplo uma conexão de água, onde o fornecedor levaria um grande tempo para fornecer essa determinada peça. Para reduzir o tempo, optou-se por fabricá-la em um impressora 3D. Assim, com a utilização de um scanner 3D, podemos escaneá-la, gerando um desenho 2D automaticamente, permitindo recriar a peça para utilização, para que a máquina onde essa peça seria ultilizada ficasse parada o menor tempo possivel.

Investigation of Debris Removal Mechanism in Ultrasonic-assisted Electrochemical Discharge Machining

2025-06-09

Anurag Shanu , Pradeep Dixit | Journal of The Electrochemical Society

Abstract Electrochemical discharge machining (ECDM) is widely used for fabricating microfeatures on brittle and non-conducting materials such as glass; however, inadequate electrolyte replenishment and debris accumulation in deep microhole drilling … Abstract Electrochemical discharge machining (ECDM) is widely used for fabricating microfeatures on brittle and non-conducting materials such as glass; however, inadequate electrolyte replenishment and debris accumulation in deep microhole drilling (>300 µm) hinder its machining performance. Ultrasonic-assisted electrochemical discharge machining (UA-ECDM) has emerged to improve electrolyte circulation and debris evacuation, thereby enhancing the machining depth. This investigation explores the influence of ultrasonic tool vibration on electrolyte flow dynamics, debris removal, and machining performance through a combined numerical and experimental approach. A 3D numerical simulation was performed to analyze electrolyte flow velocity distribution and debris movement at various vibration amplitudes. The results indicate that ultrasonic vibration doubled the electrolyte velocity and increased the debris removal efficiency by 50%. The experimental observations confirmed that ultrasonic vibration increases hole depth by 33% and improves the aspect ratio by 16% compared to conventional ECDM. High-speed imaging, current-time signals, and EDS analysis revealed that UA-ECDM minimizes debris deposition and ensures uniform discharge distribution, reducing tool wear and improving process stability. Additionally, multiple high- aspect ratio (2.5) through-holes were fabricated in a 1.1 mm thick glass substrate using a multi-tip tool electrode in UA-ECDM.

X-RAY DIFFRACTION STUDY OF RESIDUAL STRESSES IN WC-CO INDUCED BY POLARITY-SWITCHING ELECTRICAL DISCHARGE GRINDING

2025-06-05