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使用带有生物电介质和处理过的工具的旋转工具旋转工件电火花加工技术对10%碳化硅、1%碳化硅增强铝基混合复合材料进行强化加工。

Enhanced machining of Al 10%SiC 1%SiC hybrid composite using rotary tool rotary workpiece EDM with bio dielectrics and treated tools.

作者信息

Arif Umair, Ali Khan Imtiaz, Hasan Faisal

机构信息

Department of Mechanical Engineering, Aligarh Muslim University, Aligarh, India.

出版信息

Sci Rep. 2024 Oct 8;14(1):23453. doi: 10.1038/s41598-024-71713-8.

DOI:10.1038/s41598-024-71713-8
PMID:39379423
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC11461653/
Abstract

A sustainable approach was proposed to address environmental pollution, carbon footprint and economic efficiency challenges in Electrical Discharge Machining (EDM). This approach involved the use of Bio-dielectric such as biodiesel and Bio fuel (distilled water with 10% ethanol). The EDM process performance was further optimized by experimenting with both electrodes' rotation (i.e., in same direction, opposite direction, no rotation) and the use of treated tools (no treatment, heat treatment, cryogenic treatment). Biodiesel as a bio-dielectric showed promise by delivering the highest Material Removal Rate (MRR) and the lowest Tool Wear Rate (TWR). Bio-fuel (distilled water with 10% ethanol) resulted in the lowest Surface Roughness (SR) and cleaner machined surface with least carbon deposition. Additionally, electrode rotation improved flushing and enhanced performance parameters, with opposite direction rotation yielding the highest MRR and the lowest SR. However, no rotation of electrodes resulted in the lowest TWR. The use of treated tools, specifically heat-treated and cryogenically treated tools, also improved performance and reduced energy consumption, with cryogenic treatment providing the highest MRR, heat treatment giving least SR, and no treatment providing least TWR. Certain interactions between factors significantly impacted performance parameters. Grey relational analysis revealed that using distilled water with 10% ethanol as a dielectric, employing cryogenically treated copper tools, and having no rotation of both electrodes yielded the best performance parameters.

摘要

提出了一种可持续的方法来应对电火花加工（EDM）中的环境污染、碳足迹和经济效率挑战。这种方法涉及使用生物电介质，如生物柴油和生物燃料（含10%乙醇的蒸馏水）。通过对电极旋转（即同向、反向、不旋转）和使用处理过的工具（未处理、热处理、低温处理）进行试验，进一步优化了电火花加工工艺性能。生物柴油作为一种生物电介质，通过提供最高的材料去除率（MRR）和最低的工具磨损率（TWR）显示出了潜力。生物燃料（含10%乙醇的蒸馏水）产生了最低的表面粗糙度（SR）和碳沉积最少的更清洁加工表面。此外，电极旋转改善了冲洗效果并提高了性能参数，反向旋转产生了最高的MRR和最低的SR。然而，电极不旋转导致了最低的TWR。使用处理过的工具，特别是经过热处理和低温处理的工具，也提高了性能并降低了能耗，低温处理提供了最高的MRR，热处理产生了最低的SR，未处理产生了最低的TWR。因素之间的某些相互作用对性能参数有显著影响。灰色关联分析表明，使用含10%乙醇的蒸馏水作为电介质，采用低温处理的铜工具，且两个电极都不旋转，可产生最佳性能参数。

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Materials (Basel). 2022 Oct 20;15(20):7330. doi: 10.3390/ma15207330.