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Experimental investigation & optimization of micro-hardness and surface roughness under electric discharge machining: to enhance superalloy superfer 800 lightweight industrial applications
https://orcid.org/http://orcid.org/0000-0002-2891-0458
To propose a lightweight material manufacturing solution, an electric discharge machining-based experimentation study has been performed by investigating and optimizing the Superalloy Superfer 800 machinability parametric conditions. The present investigation uses graphite powder as dielectric during the electric discharge machining (EDM) setup using tool polarity, pulse on-time, pulse off-time, peak current, discharge voltage, and flushing pressure as input parameters. The objective is to evaluate and improve the machinability of the Iron-based superalloy Superfer 800 which would further increase the working life span of the component. Improved machinability could open the doors for oil, gas, and structural applications. The data from the experiments indicate that the surface roughness (SR) is improved to 51.63%, and the percentage increase in microhardness (MH) is 60.68%. The progress observed during validation for SR is from 2.15 to 1.04 μm, and for MH is from 473 to 760 HV. The SR optimal parametric setting with negative tool polarity is 3 A peak current, 20 µs pulse on time, and 25 V discharge voltage. The Conductive powder machining reduces crater formation and improves surface roughness as indicated from scanning electrode microscope (SEM) pictures. In contrast, with the tool’s positive polarity, the peak current of 9 A and pulse on-time of 20 µs show better results for MH. Finally, a confirmation validation result indicates that the average value for SR and MH is within the confidence interval.
Experimental investigation & optimization of micro-hardness and surface roughness under electric discharge machining: to enhance superalloy superfer 800 lightweight industrial applications
https://orcid.org/http://orcid.org/0000-0002-2891-0458
To propose a lightweight material manufacturing solution, an electric discharge machining-based experimentation study has been performed by investigating and optimizing the Superalloy Superfer 800 machinability parametric conditions. The present investigation uses graphite powder as dielectric during the electric discharge machining (EDM) setup using tool polarity, pulse on-time, pulse off-time, peak current, discharge voltage, and flushing pressure as input parameters. The objective is to evaluate and improve the machinability of the Iron-based superalloy Superfer 800 which would further increase the working life span of the component. Improved machinability could open the doors for oil, gas, and structural applications. The data from the experiments indicate that the surface roughness (SR) is improved to 51.63%, and the percentage increase in microhardness (MH) is 60.68%. The progress observed during validation for SR is from 2.15 to 1.04 μm, and for MH is from 473 to 760 HV. The SR optimal parametric setting with negative tool polarity is 3 A peak current, 20 µs pulse on time, and 25 V discharge voltage. The Conductive powder machining reduces crater formation and improves surface roughness as indicated from scanning electrode microscope (SEM) pictures. In contrast, with the tool’s positive polarity, the peak current of 9 A and pulse on-time of 20 µs show better results for MH. Finally, a confirmation validation result indicates that the average value for SR and MH is within the confidence interval.
Experimental investigation & optimization of micro-hardness and surface roughness under electric discharge machining: to enhance superalloy superfer 800 lightweight industrial applications
https://orcid.org/http://orcid.org/0000-0002-2891-0458
To propose a lightweight material manufacturing solution, an electric discharge machining-based experimentation study has been performed by investigating and optimizing the Superalloy Superfer 800 machinability parametric conditions. The present investigation uses graphite powder as dielectric during the electric discharge machining (EDM) setup using tool polarity, pulse on-time, pulse off-time, peak current, discharge voltage, and flushing pressure as input parameters. The objective is to evaluate and improve the machinability of the Iron-based superalloy Superfer 800 which would further increase the working life span of the component. Improved machinability could open the doors for oil, gas, and structural applications. The data from the experiments indicate that the surface roughness (SR) is improved to 51.63%, and the percentage increase in microhardness (MH) is 60.68%. The progress observed during validation for SR is from 2.15 to 1.04 μm, and for MH is from 473 to 760 HV. The SR optimal parametric setting with negative tool polarity is 3 A peak current, 20 µs pulse on time, and 25 V discharge voltage. The Conductive powder machining reduces crater formation and improves surface roughness as indicated from scanning electrode microscope (SEM) pictures. In contrast, with the tool’s positive polarity, the peak current of 9 A and pulse on-time of 20 µs show better results for MH. Finally, a confirmation validation result indicates that the average value for SR and MH is within the confidence interval.
Experimental investigation & optimization of micro-hardness and surface roughness under electric discharge machining: to enhance superalloy superfer 800 lightweight industrial applications
Int J Interact Des Manuf
Desai, Dhaval Jaydev Kumar (author) / Singh, Anoop Kumar (author) / Sharma, Ankit (author) / Kumar, Sanjeev (author)
2025-02-01
10 pages
Article (Journal)
Electronic Resource
English
Superalloy , Superfer 800 , Surface roughness , Graphite powder , Microhardness (MH) , Material removal rate (MRR) Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
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