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Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis

This paper presents the results of an investigation on the capacity of wire electrical discharge machining (WEDM) to produce microchannels in the Nickel-based alloy, Monel 400. The main objective of the current study is to produce microchannels with desired/target geometry and acceptable surface qua...

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Autores principales: Saleh, Mustafa, Anwar, Saqib, El-Tamimi, Abdualziz, Khan Mohammed, Muneer, Ahmad, Shafiq
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2020
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7281155/
https://www.ncbi.nlm.nih.gov/pubmed/32365665
http://dx.doi.org/10.3390/mi11050469
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author Saleh, Mustafa
Anwar, Saqib
El-Tamimi, Abdualziz
Khan Mohammed, Muneer
Ahmad, Shafiq
author_facet Saleh, Mustafa
Anwar, Saqib
El-Tamimi, Abdualziz
Khan Mohammed, Muneer
Ahmad, Shafiq
author_sort Saleh, Mustafa
collection PubMed
description This paper presents the results of an investigation on the capacity of wire electrical discharge machining (WEDM) to produce microchannels in the Nickel-based alloy, Monel 400. The main objective of the current study is to produce microchannels with desired/target geometry and acceptable surface quality. Square cross-sectional microchannels with dimensions of 500 × 500 µm were investigated. Experiments were conducted based on the one-factor-at-a-time approach for the key input WEDM process parameters, namely pulse-on time (TON), pulse-off time (TOFF), average gap voltage (VGAP), wire feed (WF), and dielectric flow rate (FR). Dimensional accuracy, machining speed, surface roughness, surface morphology, microhardness, and microstructure were analyzed to evaluate the microchannels. The minimum errors of 6% and 3% were observed in the width and depth of the microchannels, respectively. Furthermore, microchannels with enhanced surface integrity could be produced exhibiting smooth surface morphology and shallow recast layer (~0–2.55 µm).
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spelling pubmed-72811552020-06-15 Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis Saleh, Mustafa Anwar, Saqib El-Tamimi, Abdualziz Khan Mohammed, Muneer Ahmad, Shafiq Micromachines (Basel) Article This paper presents the results of an investigation on the capacity of wire electrical discharge machining (WEDM) to produce microchannels in the Nickel-based alloy, Monel 400. The main objective of the current study is to produce microchannels with desired/target geometry and acceptable surface quality. Square cross-sectional microchannels with dimensions of 500 × 500 µm were investigated. Experiments were conducted based on the one-factor-at-a-time approach for the key input WEDM process parameters, namely pulse-on time (TON), pulse-off time (TOFF), average gap voltage (VGAP), wire feed (WF), and dielectric flow rate (FR). Dimensional accuracy, machining speed, surface roughness, surface morphology, microhardness, and microstructure were analyzed to evaluate the microchannels. The minimum errors of 6% and 3% were observed in the width and depth of the microchannels, respectively. Furthermore, microchannels with enhanced surface integrity could be produced exhibiting smooth surface morphology and shallow recast layer (~0–2.55 µm). MDPI 2020-04-29 /pmc/articles/PMC7281155/ /pubmed/32365665 http://dx.doi.org/10.3390/mi11050469 Text en © 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Saleh, Mustafa
Anwar, Saqib
El-Tamimi, Abdualziz
Khan Mohammed, Muneer
Ahmad, Shafiq
Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title_full Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title_fullStr Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title_full_unstemmed Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title_short Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis
title_sort milling microchannels in monel 400 alloy by wire edm: an experimental analysis
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7281155/
https://www.ncbi.nlm.nih.gov/pubmed/32365665
http://dx.doi.org/10.3390/mi11050469
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