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Amused with the blissful benefits of micro-textures, researchers consider it a promising option for improving cutting tool performance, especially during machining superalloys. Through this study, the machining performance of two homothetic and six hybrid micro-textured tungsten carbide inserts have been comparatively assessed while dry turning Inconel-718. Dimple and channel micro-textures were the two independent homothetic textures. Dimple and channel micro-textures with 0°, 45°, and 90° orientation angles and a combination of triangle, square, and dimples constituted six different hybrid micro-textures. Micro-textures were fabricated on the rake face of inserts using a Ti-sapphire fired, nanosecond pulsed, infrared fiber laser. Dimple and channel micro-textured tools at 90° texture angle on rake face performed exceptionally well. Improvements in average tool life, cutting forces, and surface finish have been reported. Adhesion and attrition were the predominant forms of tool wear. Chip morphology study revealed long helical and continuous but segmented chips. [ABSTRACT FROM AUTHOR]

The rotary tool is a recent innovation of PMEDM. Aluminium oxide (Al2O3) powder with a particle concentration of 0.5–1.5 gm/l was added into the dielectric to study improved machining performance. Inconel 718 was machined using copper–tungsten electrode with tool rotation about 300 rpm. Experiments were designed using Taguchi’s three-levelL18orthogonal array. A mathematical model is developed to correlate the influences of these variables such as Peak current (Ip), Sparking gap (V), Pulse on time, (Ton), duty cycle and slurry concentration on MRR. A mean effect plots are generated to develop correlation between the influences of these variables such as Material Removal Rate, Tool Wear Rate, Surface Roughness and Heat affected zone. Recast layer affect means by Scanning Electron Microscopy (SEM). [ABSTRACT FROM AUTHOR]

The addition of conductive powders into dielectric fluid during electrical discharge machining (EDM) has significantly improved material removal rate (MRR) and surface finish for conventional materials. Further, its effectiveness continued to demonstrate for spark erosion of super alloys and metal matrix composites. This paper presents the performance of aluminium powder (Al) for machining of Inconel-718. Morphological alterations on the machined surface are investigated and reported in the discussions. Effects like powder contamination, redeposition, burning, heat affected zone are being studied. Influence of EDM control parameters is systematically experimented by using designed experiments. SEM micrographs and dispersive spectroscopy showed some contamination of aluminium powder onto a machined surface. An increase in carbon percentage has also been reported. Due to its robustness, Taguchi's orthogonal array was used for experiments. As expected, peak current, ON time and slurry concentration were the most affecting parameters on surface roughness. Simultaneously, material removal rate (MRR) was found comparatively more in powder mixed EDM than the seldom process. [ABSTRACT FROM AUTHOR]

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