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Item Effect of electrode material in wire electro discharge machining characteristics of Ti50Ni50-xCux shape memory alloy(Elsevier Inc. usjcs@elsevier.com, 2015) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.N.Abstract TiNiCu alloy belongs to new class of shape memory alloy (SMA), which exhibits superior properties like shape memory effect, super elasticity and reversible martensitic transformation phase and thus find broad applications in actuators, micro tools and stents in biomedical components. Even though, SMA demonstrates outstanding property profile, traditional machining of SMAs is fairly complex and hence non-traditional machining like wire electric discharge machining (WEDM) has been performed. Hence, there is a need to investigate the WEDM performance characteristics of shape memory alloys due to excellent property profile and potential applications. In the present investigation, various machining characteristics like material removal rate (MRR), surface roughness, surface topography and metallographic changes have been studied and the influence of wire material on TiNiCu alloy machining characteristics has also been evaluated through ANOVA. Ti50Ni50-xCux=10, 20 was prepared by vacuum arc melting process. The proposed alloy as-cast material exhibits austenite property (B2 phase) and having higher hardness when compared to TiNi alloy. The investigation on WEDM of Ti50Ni50-xCux alloy reveals that the machining parameters such as servo voltage, pulse on time and pulse off time are the most significant parameters affecting MRR as well as surface roughness using both brass and zinc coated brass wires. However, machining with zinc coated brass wire yields reduced surface roughness and better MRR and also produces less surface defects on the machined surface of Ti50Ni50-xCux alloys. © 2015 Elsevier Inc. All rights reserved.Item Influence of process parameters on material removal rate and surface roughness in WED-machining of Ti50Ni40Cu10 shape memory alloy(Inderscience Publishers, 2016) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.N.Among the shape memory alloys (SMAs), TiNi SMAs have been typically used as the functional elements in the larger part of the industries due to exceptional properties like super elasticity and shape memory effect. However, traditional machining of these alloys is fairly complex due to these properties. The non-traditional machining process like electric discharge machining (EDM) exhibits outstanding capability in machining of these alloys. The poor selection of machining parameters may cause increased roughness of workpiece and lesser material removal rate. Hence, an effort has been made in the present work to explore the effects of three process parameters, such as pulse on time, pulse off time and servo voltage in wire electric discharge machining (WEDM) of Ti50Ni40Cu10 shape memory alloy (SMA) using zinc coated brass wire electrode on material removal rate and surface roughness using response surface methodology (RSM)-based mathematical models. The experiments were planned as per central composite design (CCD). The investigations revealed that pulse on time and servo voltage have predominant effects in maximising material removal rate and minimising surface roughness. The best combination of the process parameters for multi-response optimisation was obtained through desirability function. ©2016 Inderscience Enterprises Ltd.Item Investigation on material removal rate, surface and subsurface characteristics in wire electro discharge machining of Ti50Ni50-xCux shape memory alloy(SAGE Publications Ltd info@sagepub.co.uk, 2018) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.TiNiCu shape memory alloys have superior properties as compared with NITINOL due to their greater ductility, reduced hysteresis temperature range, and quick actuation response. The present article investigates the surface and subsurface modifications occurring due to wire electro discharge machining of Ti50Ni50-xCux shape memory alloy. The machining experiments were performed considering the pulse on time, pulse off time, and servo voltage as the process parameters. The influence of these parameters was studied on the material removal rate, surface roughness, recast layer thickness, microhardness, and phase changes in the machined surface. Longer pulse on time causes greater discharge energy, hence leading to higher material removal rate, surface roughness, and recast layer thickness. The machined surface hardness increased up to 900 Hv, which is about 59% increase with respect to the base material for longer pulse on time due to the recast layer thickness and the formation of oxides. A phase change on the machined surface was observed to cause the shape recoverability of the alloy. The microstructure, composition through EDAX, and the phase changes of the machined surface are also discussed in the article. © 2015, © IMechE 2015.Item Experimental Investigation on Effects of Wire Electro Discharge Machining of Ti50Ni45Co5 Shape Memory Alloys(Springer Netherlands rbk@louisiana.edu, 2018) Soni, H.; Narendranath, S.; Ramesh, M.R.TiNiCo shape memory alloy is most popular shape memory alloy for biomedical applications due to their outstanding properties such as shape memory effect, pseudoelasticity and transformation temperature. Machining of such kind of alloys is very difficult through conventional machining process is very difficult because they may affect their internal properties of these alloys. However conventional machining processes give poor surface quality during the machining hence non-conventional machining processes such as (wire electro discharge machining, water jet machining and electro discharge machining etc.) are more suitable for machining of such kind of alloy. From the literature it has been found that Wire electro discharge machining (WEDM) is more suitable non-conventional machining process for such kind of alloy. Present study exhibits the effects WEDM characteristics of Ti50Ni45Co5 shape memory alloy. L-9 orthogonal array has been created by using Taguchi as a design method for machining of selected alloy and machined surface characterization has been carried out at the optimized process parameters with respect to microstructures, surface topography, microhardness, XRD analysis and residual stresses. To find the optimum setting of the input process parameters a couple of optimization techniques are used, namely principal component analysis (PCA) and Gray relational analysis (GRA) technique. 125?s pulse on time (Ton), 35?s pulse off time (Toff) and 40V servo voltage (SV) were found as an optimal setting for the higher material removal rate (MRR) with better surface roughness (SR) in the present study. Moreover, characterization of the machined surface is performed with respect to microstructures, surface topography, microhardness analysis, XRD and residual stresses. Harder surface observed near the cutting edge and TiNio3 Tio2 and CuZn were noticed on the surface of machined component through XRD analysis. However, compressive residual stress has been noticed on the machined surface during WEDM process. © 2018, Springer Science+Business Media B.V., part of Springer Nature.Item Impact of variation in wire electro discharge machining responses of homologous TiNiCu shape memory alloys for smart applications: An experimental investigation(Institute of Physics Publishing helen.craven@iop.org, 2018) Roy, A.; Narendranath, S.In this study, three distinct TiNiCu alloys were processed using wire electro discharge machining. These alloys are potential materials for smart applications owing to their fast actuation response resulting from suitable martensitic transformation temperatures. Due to differences in their physical property (thermal conductivity in this case), these alloys exhibit variation in machining response during wire electro discharge machining. Based on wire electro discharge machining responses of these alloys, order of thermal conductivity of these alloys are concluded in this study. This investigation aims at addressing the variation in terms of kerf width, recast layer thickness and machined surface microhardness to form the basis for production of intricate components. Ti50Ni40Cu10 alloy exhibited diverging machining response compared to its counterparts. Influential parameter for a given machining response changes depending on thermal property of the workpiece which makes it vital to investigate and choose the parameters in a more sensible manner while machining such materials. It was found that kerf width decreases with increasing servo voltage whereas recast layer thickness (mostly influenced by pulse off duration) increases with increasing pulse off duration. Microhardness of the machined surface (mostly influenced by pulse on duration) increases at higher discharge energy levels owing to presence of oxides formed during spark erosion process. Microhardness of Ti40Ni50Cu10 was found to be high (approximately 560 Hv) compared to its counterparts which was due to presence of Ni rich and ?-CuTi precipitates which also affected its phase transformation temperatures. © 2018 IOP Publishing Ltd.Item Effect of peak current and peak voltage on machined surface morphology during WEDM of TiNiCu shape memory alloys(Korean Society of Mechanical Engineers, 2020) Roy, A.; Narendranath, S.; Pramanik, A.This study considers the effect of wire electro discharge machining (WEDM) parameter peak current (Ip) and pulse peak voltage (Vp) on the machined surface morphology of TiNiCu shape memory alloys. Various defects of machined surfaces were identified and correlated with parameter values and measured average surface roughness (Ra) and average surface depth (Rz). It was found that the nature of the machined surface is highly influenced by the nature of sparking, which is dictated by levels of peak current and peak voltage used during machining. Distinctions between machining parameters resulting in “rough-cut” and “trim-cut” machining are reported along with deviations in output responses, which counters the trend reported in the literature. © 2020, The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature.