Farooq Hassan, Pasha Riffat Asim
Mechanical Engineering Deptt, University of Engineering & Technology, Taxila, Pakistan.
Heliyon. 2024 Aug 21;10(17):e36459. doi: 10.1016/j.heliyon.2024.e36459. eCollection 2024 Sep 15.
The manufacturing industry is currently grappling with issues related to energy dissipation and product quality, both of which significantly impact productivity. In addressing this pertinent concern, this study endeavours to identify the key indicators that contribute a crucial role in machining process. The Dry EDM (DEDM) emerges as a novel technology, wherein environmentally friendly gases serve as an alternative dielectric medium instead of liquid EDM approaches. In conventional EDM process, hydrocarbon oils release toxic emissions while the gases used in Dry EDM process don't produce harmful emissions and hence make the DEDM process sustainable. An investigation has been carried out to observe the influence of different gases like O2, N2 and Air on Siliconized Silicon-Carbide plate (SiSiC) of ø50mm*2 mm under Dry Electrical Discharge Machining. Effect of different tools is also observed using varying shapes of electrodes like plane Cu electrode of ø6 mm diameter with 60 mm length and tubular shape with outer diameter ø6mm and inner diameter ø5.1 mm with a length of 60 mm. The three gases are one by one supplied through a nozzle in the presence of plane Cu electrode to make the holes in SiSiC plate. The same process is executed with tubular Cu electrode. Modified Taguchi Orthogonal Array is applied to analyze the effect of control factors such as gap voltage, discharge current and pulse on-time through a series of experiments. Effect of different shape of tools and different gases is observed for the material removal rate (MRR) and surface roughness (SR) of specimen. In this paper, a latest DEDM process of swirl assisted flushing is proposed which provides a new technique to solve the problems of low MRR and poor surface integrity. Swirl assisted flushing works on Decay Law and also microscopic investigation justifies its validity. It is concluded by this research that current and Pulse on time are more contributing factors about 53.3 % and 27 % respectively. Furthermore, it is noted that DEDM increases MRR 19.5 % and lowers Ra approximately 2/3 than traditional machining. The MRR of O2 is about 3.1 times more than Air and N2 comes at least position while N2 creates better quality of surface due to formation of an inert nitride layer. Empirical relations are established for SR and MRR using Minitab 18 Software to develop a robust model. Confirmation test is performed to check the validity of developed mathematical model. The Novelty of this research is also extended by introducing a new method SAF. The results are finally evaluated by ANOVA.
制造业目前正面临与能量耗散和产品质量相关的问题，这两个因素都对生产率有重大影响。为了解决这一相关问题，本研究致力于确定在加工过程中起关键作用的关键指标。干式电火花加工（DEDM）作为一种新技术出现，其中环保气体作为替代介电介质，取代了液体电火花加工方法。在传统电火花加工过程中，烃油会释放有毒排放物，而干式电火花加工过程中使用的气体不会产生有害排放物，因此使DEDM过程具有可持续性。已经进行了一项研究，以观察在干式放电加工过程中，不同气体（如氧气、氮气和空气）对直径为ø50mm*2mm的硅化碳化硅板（SiSiC）的影响。还使用不同形状的电极（如直径为ø6mm、长度为60mm的平面铜电极和外径为ø6mm、内径为ø5.1mm、长度为60mm的管状电极）观察不同工具的效果。在平面铜电极存在的情况下，通过喷嘴逐一供应这三种气体，在SiSiC板上打孔。使用管状铜电极执行相同的过程。应用改进的田口正交阵列，通过一系列实验分析诸如间隙电压、放电电流和脉冲导通时间等控制因素的影响。观察不同形状的工具和不同气体对试样的材料去除率（MRR）和表面粗糙度（SR）的影响。本文提出了一种最新的涡旋辅助冲洗式DEDM工艺，该工艺提供了一种解决低MRR和表面完整性差问题的新技术。涡旋辅助冲洗遵循衰减定律，微观研究也证明了其有效性。本研究得出结论，电流和脉冲导通时间是更具影响的因素，分别约为53.3%和27%。此外，值得注意的是，与传统加工相比，DEDM使MRR提高了19.5%，使Ra降低了约2/3。氧气的MRR约为空气的3.1倍，氮气的MRR最低，而氮气由于形成惰性氮化物层而产生更好的表面质量。使用Minitab 18软件建立了SR和MRR的经验关系，以开发一个稳健的模型。进行确认试验以检验所开发数学模型的有效性。本研究的新颖性还体现在引入了一种新方法SAF上。最后通过方差分析对结果进行评估。
