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Electro-Discharge Machining of Inconel 825 Super alloy: Effects of Tool Material and Dielectric Flushing

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Abstract

Aspects of machinability of Inconel 825 super alloy during electro-discharge machining was attempted in this work. The extent of machinability was investigated in purview of process performance (i.e. material removal rate), surface integrity (morphology as well as topography) of the EDMed work surface including surface roughness, surface crack density, white layer thickness, and micro-indentation hardness. Effects of variation of tool material (graphite, tungsten, brass and copper) were analyzed in this work. Metallurgical characteristics of the EDMed work surface were studied in view of phase information (matrix and precipitates), grain refinement (crystallite size, micro-strain and dislocation density) etc. Results were further interpreted in support of EDS, and micro-hardness test data. Additionally, effects of flushing condition (with and without flushing) of the dielectric medium were examined on influencing EDM performance on Inconel 825 work material. Moreover, effects of peak discharge current on EDM responses were discussed.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Jadavpur University, Kolkata, 700032, India

    Soni Kumari, Goutam Nandi & Pradip Kumar Pal

  2. Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769008, Odisha, India

    Saurav Datta & Manoj Masanta

Authors
  1. Soni Kumari
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  2. Saurav Datta
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  3. Manoj Masanta
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  4. Goutam Nandi
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  5. Pradip Kumar Pal
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Corresponding author

Correspondence to Saurav Datta.

Appendices

Appendix I

$$\begin{array}{@{}rcl@{}} SCD=\frac{Total\,crack\,lenght}{Area\,\,of\,micrograph}\,&=&\,\frac{0.35}{0.045\times 1000}\,\\&=&\,0.00777778\,\,\frac{\mu m}{\mu m^{2}}\, \end{array} $$
Fig. 21
figure 21

Measurement of SCD of the EDMed work surface of Inconel 825 obtained at IP = 10A, using Tungsten tool electrode

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APPENDIX II

$$\begin{array}{@{}rcl@{}} WLT\,&=&\,\frac{Area\,\,(A)}{Length\,of\,the\,\,micrograph\,\,(L)}\\ WLT&=&\frac{Area(A)}{Length(L)}=\frac{5517.883\mu m^{2}}{250\mu m}= 22.071\mu m \end{array} $$
Fig. 22
figure 22

Measurement of WLT of the EDMed work surface of Inconel 825 obtained at IP = 10A, using Tungsten tool electrode

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APPENDIX III

Fig. 23
figure 23

Place of indentation for micro-hardness test of the EDMed Inconel 825 obtained by using brass electrode at IP = 8A

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Kumari, S., Datta, S., Masanta, M. et al. Electro-Discharge Machining of Inconel 825 Super alloy: Effects of Tool Material and Dielectric Flushing. Silicon 10, 2079–2099 (2018). https://doi.org/10.1007/s12633-017-9728-5

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  • DOI: https://doi.org/10.1007/s12633-017-9728-5

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