氧化铝纳米粉末混合介电油对电火花辅助精密微钻孔操作影响的研究

Deepak Agarwal, Sharad Yadav, Rabesh Kumar Singh, Anuj Kumar Sharma
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引用次数: 0

摘要

在现代工业时代,微孔和钻孔工件的尺寸必须更加精确。制造汽车和航空航天部件中使用的具有散热性能的微型电子设备,以及具有杀菌性能的生物医学设备,都需要在类铜材料上进行微钻孔加工。微电钻已成为一种前景广阔的微钻孔技术。µ-EDM钻孔面临的主要挑战是如何有效地消除碎片(工件和工具的碎片)。因此,本研究旨在研究可行的参数组合(放电能量、刀具进给速率、刀具旋转和纳米粉体),以便在微电火花加工中使用碳化钨微电极在铜上钻出尺寸正确、表面特征更好的 µ 通孔。此外,本研究还考察了 Al2O3 纳米粉体混合电介质对工艺性能方面的影响。方差分析和 PCA-GRA 多重优化技术解决了性能方面(MRR、TWR 和加工时间)和尺寸方面(过切、锥角和纵横比)的问题,并实现了表面可视化(纹理和重铸层)。实验发现,纳米粉体混合电介质对尺寸方面的影响很大(过切增加 55.13%,锥角减少 37.9%),使总重量降低 12.2%,纵横比降低 3.31%。此外,放电能量对 MRR 的影响增加了 27.9%,加工时间缩短了 3.48%。FESEM 显微照片显示,使用纳米粉体混合介电质后,表面缺陷(裂纹、空洞、放电气泡、碎屑堆积等)大部分被消除,重铸层厚度减少了 34.4%(放电能量为 2.81 µj DE 时)和 56.6%(放电能量为 7.81 µj DE 时)。
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An investigation on the effect of alumina nano powder mixed dielectric oil on EDM-assisted precision micro-drilling operation
Micro-holes and drilled workpiece dimensions must be more exact in the modern industrial age. Manufacturing micro-scale electronic devices used in automobiles and aerospace components with thermal sinking properties and bio-medical with germicidal properties requires micro-drilling on copper-like materials. Micro-EDM has emerged as a promising technique for micro-drilling. The primary challenge faced in µ-EDM drilling is the effective elimination of debris (mass of workpiece and tool). Therefore, this study aims to investigate the feasible parametric combination (Discharge Energy, Tool Feed Rate, Tool Rotation, and Nano-Powder) to achieve dimensionally correct with better surface characteristic µ-through holes in copper using tungsten carbide micro electrode in micro-EDM. Furthermore, this study examines the effect of Al2O3 nano-powder mixed dielectric on the process performance aspects. ANOVA and PCA-GRA multi-optimization techniques addressed performance aspects (MRR, TWR, and Machining Time) and dimensional aspects (Overcut, Taper Angle, and Aspect Ratio) with visualization of the surface (Texture and Recast Layer). The experimentation found that nano-powder mixed dielectric highly impacted dimensional aspects (Overcut increased by 55.13%, Taper Angle reduced by 37.9%) by diminishing TWR by 12.2% and aspect Ratio by 3.31%. Furthermore, discharge energy affects MRR by increasing 27.9%, and machining time is reduced by 3.48%. The FESEM micrograph illustrated that surface defects (cracks, voids, discharge bubbles, debris accumulations, etc.) were most eliminated, and recast layer thickness was reduced by 34.4% (at 2.81 µj DE) and 56.6% (at 7.81 µj DE) using nano-powder mixed dielectric application.
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来源期刊
CiteScore
3.80
自引率
16.70%
发文量
370
审稿时长
6 months
期刊介绍: The Journal of Process Mechanical Engineering publishes high-quality, peer-reviewed papers covering a broad area of mechanical engineering activities associated with the design and operation of process equipment.
期刊最新文献
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