Surface characteristics optimization and investigation of dual-channel micro electrical discharge drilling on IN617 super alloy

Anish Nair , Wojciech Bizoń , Sebastian Skoczypiec , Rafal Bogucki , L. Selvarajan
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Abstract

This article details the experimental investigation on surface roughness, spatter area and white layer thickness in micro electrical discharge machining of IN617 alloy. The alloy here is a high hardness superalloy preferred to be machined by non-conventional techniques. Here we present the micromachining behaviour of the alloy. Micro electrical discharge machining is conducted using a dual channel copper electrode and the surface characteristics are observed. Other than the traditional input factors, retraction duration of the electrode is also focussed here. White layer characteristics at different heights of the drilled hole are measured and characterized. Intensive microscopic images have been presented to detail the behaviour of the process. The behaviour of individual responses towards the various input factors has been illustrated. A multiobjective optimization model is also developed to extract the best parametric combinations at which optimal surface characteristics can be obtained.The major factor affecting the spatter area and white layer thickness is Pulse on time. The increase in pulse on time creates a high frequency of sparks which leads to rapid metal erosion at the vicinity of the electrode. In the case of surface roughness, the current was observed as the most dominant factor which corresponds to earlier studies on similar processes. Detailed microstructural analysis depicting heat affected zone, white layer thickness and surface deformities have been reported to understand the mechanism of the process.
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本文详细介绍了微放电加工 IN617 合金时表面粗糙度、飞溅面积和白层厚度的实验研究。该合金是一种高硬度超级合金,适合采用非常规技术进行加工。我们在此介绍该合金的微加工性能。我们使用双通道铜电极进行微放电加工,并观察其表面特征。除了传统的输入因素外,电极的回缩时间也是重点。对钻孔不同高度的白层特征进行了测量和表征。此外,还提供了大量显微图像,以详细说明加工过程的行为。还说明了对各种输入因素的个别反应行为。此外,还开发了一个多目标优化模型,以提取可获得最佳表面特征的最佳参数组合。脉冲接通时间的增加会产生高频率的火花,从而导致电极附近的金属快速侵蚀。在表面粗糙度方面,观察到电流是最主要的因素,这与之前对类似工艺的研究一致。详细的微观结构分析描绘了热影响区、白层厚度和表面变形,以了解该过程的机理。
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