Electric discharge machining parameter optimization for Nimonic C-263 using aluminium powder-infused green dielectric

IF 2.1 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY

Bulletin of Materials Science Pub Date : 2025-06-27 DOI:10.1007/s12034-025-03438-x

PRASAN RALPH DEWAN, PRANAB KUMAR KUNDU

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Abstract

One of the non-traditional techniques for processing hard and electrically conductive materials is the powder-mixed electric discharge machining, which involves no physical connection between the tool and work surface. Nimonic C-263, a nickel-based superalloy, is widely used in aerospace and automobile sectors due to its improved inherent properties such as high hardness at elevated temperatures, high creep and corrosion resistance and excellent intermediate temperature tensile ductility. This study investigates aluminium powder-mixed electric discharge machining of Nimonic C-263 while using non-toxic environment friendly dielectric, deionized water. The effects of altering parameters such as peak current (I_pc), pulse-on-time (T_on), pulse-off-time (T_off) and powder concentration (C) on material removal rate (MRR), tool wear rate (TWR) and average surface roughness (R_a) have been critically analysed. The observations show a rise in MRR with the increase in I_pc, T_on and C. R_a is found to increase with an elevation in I_pc and T_on while it declines with a rise in C. Process parameter optimization through grey relational analysis reveals the best parametric combination as I_pc = 8 A, T_on = 1 µs, T_off = 5 µs and C = 9 kg m⁻³. SEM analyses depict that the surface quality deteriorates at higher values of I_pc.

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注入铝粉绿色介质的Nimonic C-263电火花加工参数优化

粉末混合电火花加工是加工硬质材料和导电材料的一种非传统技术，它不涉及刀具和工作表面之间的物理连接。Nimonic C-263是一种镍基高温合金，由于其在高温下的高硬度、高蠕变和耐腐蚀性以及优异的中温拉伸延展性等固有性能的改进，被广泛应用于航空航天和汽车领域。研究了在无毒环保介质去离子水的条件下，铝粉混合电火花加工Nimonic C-263。改变诸如峰值电流（Ipc）、脉冲接通时间（Ton）、脉冲关闭时间（Toff）和粉末浓度(C)等参数对材料去除率（MRR）、刀具磨损率（TWR）和平均表面粗糙度（Ra）的影响进行了严格分析。MRR随Ipc、Ton和C的增加而增加，Ra随Ipc和Ton的增加而增加，而随C的增加而下降。通过灰色关联分析优化工艺参数，发现Ipc = 8 a, Ton = 1µs, Toff = 5µs, C = 9 kg m - 3为最佳参数组合。SEM分析表明，Ipc值越高，表面质量越差。

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来源期刊

Bulletin of Materials Science 工程技术-材料科学：综合

CiteScore

3.40

自引率

5.60%

发文量

209

审稿时长

11.5 months

期刊介绍： The Bulletin of Materials Science is a bi-monthly journal being published by the Indian Academy of Sciences in collaboration with the Materials Research Society of India and the Indian National Science Academy. The journal publishes original research articles, review articles and rapid communications in all areas of materials science. The journal also publishes from time to time important Conference Symposia/ Proceedings which are of interest to materials scientists. It has an International Advisory Editorial Board and an Editorial Committee. The Bulletin accords high importance to the quality of articles published and to keep at a minimum the processing time of papers submitted for publication.