Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy
Abstract
:1. Introduction
2. Synthesis of Nano-Graphene Powder
2.1. Reagents and Instrumentation
2.2. Synthesis of Graphene Using Carbon Source
3. Materials and Methods
4. Results and Discussions
4.1. Nano-Graphene Powder
4.2. Regression Equations
4.3. Analysis of MRR
4.4. Analysis of SR
4.5. Optimization Using HTS Algorithm
4.5.1. Conduction Phase
4.5.2. Convection Phase
4.5.3. Radiation Phase
4.6. Effect of Nano-Graphene Powder on Response Variables
4.7. Effect of Nano-Graphene Powder on Surface Morphology of Machined Surface
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
ANOVA | Analysis of variance |
DCB | Dichlorobenzene |
DF | Degree of freedom |
DOE | Design of Experiments |
EDM | Electrical Discharge Machining |
FESEM | Field emission scanning electron microscope |
HTS | Heat transfer search |
MOHTS | Multi-objective heat transfer search |
MRR | Material removal rate (mm3/s) |
NPMWEDM | Nano-powder mixed wire electrical discharge machining |
PMEDM | Powder mixed electrical discharge machining |
SEM | Scanning electron microscope |
SMA | Shape memory alloy |
SMAs | Shape memory alloys |
SR | Surface roughness (µm) |
TEM | Transmission electron microscope |
Ton | Pulse on time (µs) |
Toff | Pulse off time (µs) |
WEDM | Wire electric discharge machine |
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Element | Ti | Ni | Co | Cu | Cr | Fe | Nb | C | H | O | N |
---|---|---|---|---|---|---|---|---|---|---|---|
wt (%) | Balance | 55.78 | 0.005 | 0.005 | 0.005 | 0.012 | 0.005 | 0.039 | 0.001 | 0.0344 | 0.001 |
Working Condition | Description |
---|---|
Current (A) | 1, 2, 3, 4 |
Pulse on time (µs) | 30, 40, 50, 60 |
Pulse off time (µs) | 10, 14, 18, 22 |
Powder concentration (g/L) | 0.25, 0.50, 0.75, 1 |
Graphene nano powder-size (nm) | 300–500 |
Powder | Graphite |
Wire | Molybdenum |
Run | Current (A) | Ton (µs) | Toff (µs) | Powder Conc. (g/L) | MRR (mm3/s) | SR (µm) |
---|---|---|---|---|---|---|
1 | 1 | 30 | 10 | 0.25 | 0.1891 | 4.33 |
2 | 1 | 40 | 14 | 0.5 | 0.3293 | 4.88 |
3 | 1 | 50 | 18 | 0.75 | 0.4135 | 5.16 |
4 | 1 | 60 | 22 | 1 | 0.4184 | 4.98 |
5 | 2 | 30 | 14 | 0.75 | 0.2155 | 4.22 |
6 | 2 | 40 | 10 | 1 | 0.4502 | 5.11 |
7 | 2 | 50 | 22 | 0.25 | 0.2596 | 4.99 |
8 | 2 | 60 | 18 | 0.5 | 0.5472 | 6.02 |
9 | 3 | 30 | 18 | 1 | 0.2294 | 4.12 |
10 | 3 | 40 | 22 | 0.75 | 0.3147 | 4.8 |
11 | 3 | 50 | 10 | 0.5 | 0.5557 | 5.97 |
12 | 3 | 60 | 14 | 0.25 | 0.4940 | 6.3 |
13 | 4 | 30 | 22 | 0.5 | 0.2142 | 4.17 |
14 | 4 | 40 | 18 | 0.25 | 0.3592 | 5.7 |
15 | 4 | 50 | 14 | 1 | 0.6240 | 6.04 |
16 | 4 | 60 | 10 | 0.75 | 0.7410 | 6.52 |
Source | DF | SS | MS | F | P | Contribution (%) |
---|---|---|---|---|---|---|
Current | 3 | 0.048154 | 0.016051 | 18.92 | 0.019 | 12.04 |
Ton | 3 | 0.252635 | 0.084212 | 99.25 | 0.002 | 63.18 |
Toff | 3 | 0.068354 | 0.022785 | 26.85 | 0.011 | 17.09 |
Powder Conc. | 3 | 0.028141 | 0.009380 | 11.06 | 0.040 | 7.03 |
Error | 3 | 0.002545 | 0.000848 | 0.66 | ||
Total | 15 | 0.399831 | ||||
S = 0.02912, R-Sq = 99.36%, R-Sq (Adj) = 96.82% |
Source | DF | SS | MS | F | P | Contribution (%) |
---|---|---|---|---|---|---|
Current | 3 | 1.28002 | 0.42667 | 21.19 | 0.016 | 13.50 |
Ton | 3 | 6.68617 | 2.22872 | 110.66 | 0.001 | 70.51 |
Toff | 3 | 1.29577 | 0.43192 | 21.45 | 0.016 | 13.66 |
Powder Conc. | 3 | 0.15937 | 0.05312 | 2.64 | 0.223 | 1.68 |
Error | 3 | 0.06042 | 0.02014 | 0.65 | ||
Total | 15 | 9.48174 | ||||
S = 0.141914, R-Sq = 99.26%, R-Sq (Adj) = 96.8% |
Objective Function | Design Variables | Objective Function | ||||
---|---|---|---|---|---|---|
Current (A) | Pulse on Time (µs) | Pulse off Time (µs) | Powder Conc. (g/L) | MRR (mm3/s) | SR (µm) | |
Maximum MRR | 6 | 110 | 1 | 1 | 1.5507 | 10.51 |
Minimum SR | 1 | 1 | 8 | 1 | 0.0001 | 2.68 |
Sr. No. | Current (A) | Pulse on Time (µs) | Pulse off Time (µs) | Powder Conc. (g/L) | MRR (mm3/s) | SR (µm) |
---|---|---|---|---|---|---|
1 | 1 | 1 | 8 | 1 | 0.00013 | 2.67 |
2 | 1 | 1 | 6 | 1 | 0.02889 | 2.79 |
3 | 1 | 1 | 4 | 1 | 0.04363 | 2.95 |
4 | 1 | 1 | 2 | 1 | 0.08619 | 3.03 |
5 | 1 | 2 | 1 | 1 | 0.11150 | 3.14 |
6 | 1 | 6 | 3 | 1 | 0.12770 | 3.25 |
7 | 1 | 7 | 2 | 1 | 0.15313 | 3.37 |
8 | 1 | 12 | 3 | 1 | 0.19456 | 3.59 |
9 | 1 | 10 | 1 | 1 | 0.20095 | 3.59 |
10 | 1 | 14 | 2 | 1 | 0.23102 | 3.76 |
11 | 1 | 18 | 4 | 1 | 0.24660 | 3.87 |
12 | 1 | 18 | 1 | 1 | 0.28983 | 4.05 |
13 | 1 | 22 | 2 | 1 | 0.31991 | 4.21 |
14 | 2 | 23 | 3 | 1 | 0.36399 | 4.46 |
15 | 4 | 15 | 2 | 1 | 0.38370 | 4.57 |
16 | 4 | 17 | 2 | 1 | 0.40580 | 4.69 |
17 | 1 | 32 | 1 | 1 | 0.44609 | 4.84 |
18 | 3 | 29 | 2 | 1 | 0.49244 | 5.11 |
19 | 1 | 40 | 1 | 1 | 0.53524 | 5.29 |
20 | 2 | 40 | 3 | 1 | 0.55342 | 5.42 |
21 | 3 | 36 | 1 | 1 | 0.58469 | 5.57 |
22 | 2 | 45 | 3 | 1 | 0.60132 | 5.73 |
23 | 2 | 53 | 2 | 1 | 0.71254 | 6.22 |
24 | 1 | 58 | 1 | 1 | 0.73567 | 6.31 |
25 | 1 | 62 | 1 | 1 | 0.78033 | 6.53 |
26 | 1 | 65 | 1 | 1 | 0.81375 | 6.70 |
27 | 1 | 68 | 1 | 1 | 0.84708 | 6.87 |
28 | 2 | 68 | 2 | 1 | 0.87979 | 7.07 |
29 | 2 | 71 | 1 | 1 | 0.92738 | 7.30 |
30 | 1 | 78 | 1 | 1 | 0.95819 | 7.44 |
31 | 3 | 72 | 1 | 1 | 0.98581 | 7.60 |
32 | 2 | 79 | 1 | 1 | 1.01645 | 7.75 |
33 | 1 | 92 | 1 | 1 | 1.11416 | 8.23 |
34 | 4 | 81 | 1 | 1 | 1.13310 | 8.36 |
35 | 1 | 96 | 1 | 1 | 1.15895 | 8.46 |
36 | 2 | 95 | 1 | 1 | 1.19466 | 8.65 |
37 | 2 | 100 | 1 | 1 | 1.25053 | 8.93 |
38 | 1 | 107 | 1 | 1 | 1.28130 | 9.08 |
39 | 1 | 110 | 1 | 1 | 1.31493 | 9.25 |
40 | 3 | 103 | 2 | 1 | 1.31678 | 9.30 |
41 | 2 | 110 | 2 | 1 | 1.34733 | 9.44 |
42 | 4 | 103 | 1 | 1 | 1.37833 | 9.61 |
43 | 4 | 105 | 1 | 1 | 1.40027 | 9.72 |
44 | 4 | 107 | 1 | 1 | 1.42276 | 9.83 |
45 | 5 | 106 | 1 | 1 | 1.45891 | 10.03 |
46 | 5 | 108 | 1 | 1 | 1.48100 | 10.14 |
47 | 5 | 110 | 1 | 1 | 1.50357 | 10.26 |
48 | 6 | 110 | 1 | 1 | 1.55070 | 10.51 |
Sr. No. | Current (A) | Pulse on Time (µs) | Pulse off Time (µs) | Powder Conc. (g/L) | Predicted Values by HTS Algorithm | Experimentally Measured Values | % Deviation | |||
---|---|---|---|---|---|---|---|---|---|---|
MRR | SR | MRR | SR | MRR | SR | |||||
1 | 1 | 1 | 8 | 1 | 0.00013 | 2.67 | 0.00014 | 2.81 | 3.52 | 4.98 |
11 | 1 | 18 | 4 | 1 | 0.24660 | 3.87 | 0.24151 | 4.01 | 2.10 | 3.49 |
23 | 2 | 53 | 2 | 1 | 0.71254 | 6.22 | 0.73004 | 6.1 | 2.39 | 1.97 |
40 | 3 | 103 | 2 | 1 | 1.31678 | 9.30 | 1.35321 | 9.73 | 2.69 | 4.41 |
48 | 6 | 110 | 1 | 1 | 1.55070 | 10.51 | 1.49452 | 10.93 | 3.75 | 3.84 |
Condition | Input Process Parameters | Response Variables |
---|---|---|
With addition of Nano-graphene powder at 1 g/L | Current = 1 A Pulse on time = 30 µs Pulse on time = 22 µs Powder conc. = 1 g/L | MRR = 0.12187 mm3/s SR = 3.4945 µm |
Without Nano-graphene powder | Current = 1 A Pulse on time = 30 µs Pulse on time = 22 µs Powder conc. = 0 g/L | MRR = 0.09051 mm3/s SR = 3.85 µm |
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Chaudhari, R.; Vora, J.; López de Lacalle, L.N.; Khanna, S.; Patel, V.K.; Ayesta, I. Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy. Materials 2021, 14, 2533. https://doi.org/10.3390/ma14102533
Chaudhari R, Vora J, López de Lacalle LN, Khanna S, Patel VK, Ayesta I. Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy. Materials. 2021; 14(10):2533. https://doi.org/10.3390/ma14102533
Chicago/Turabian StyleChaudhari, Rakesh, Jay Vora, L.N. López de Lacalle, Sakshum Khanna, Vivek K. Patel, and Izaro Ayesta. 2021. "Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy" Materials 14, no. 10: 2533. https://doi.org/10.3390/ma14102533