Abstract
The concern of this experimental work is to study the surface integrity aspects such as surface morphology, three-dimensional surface topography, recast layer, phase analysis, and micro-hardness for Ni55.95Ti44.05 shape memory alloy at the optimized level of wire electric discharge machining parameters. A mathematical model was developed for surface roughness and material removal rate considering servo voltage, pulse on time, wire tension, wire feed rate, and pulse off time using response surface methodology technique. In order to obtain the optimized parameters, multi-objective optimization technique grey relation analysis was utilized. The adequacy of the developed model was also checked by analysis of variance. At optimal parameters setting, i.e., pulse on time 123 µs, pulse off time 58 µs, servo voltage 50 V, wire tension 3 N, and wire feed rate 5 m/min, maximum material removal rate (8.223 mm3/min) and minimum surface roughness (1.93 µm) were achieved. Surface characteristics of machined surface divulge the presence of discharge craters, debris, molten droplets, micro-voids, spherical nodules, and cracks. A recast layer of thickness 19 µm with approximately 21% of foreign elements was deposited on the machined surface at optimized parameters, whereas the micro-hardness of the outer machined surface was found to be increased approximately 1.98 times as compared to micro-hardness of bulk material. X-ray diffraction analysis shows the presence of the following compounds on the machined surface NiTi, Ni4Ti3, Ti4O3, Cu5Zn8, Ni(TiO3), and NiZn.
Similar content being viewed by others
Abbreviations
- T ON :
-
Pulse on time (μs)
- T OFF :
-
Pulse off time (μs)
- W g :
-
Spark gap
- d :
-
Wire diameter
- WEDM:
-
Wire electric discharge machining
- SMA:
-
Shape memory alloy
- SV:
-
Servo voltage (V)
- WT:
-
Wire tension (N)
- WF:
-
Wire feed rate (m/min)
- MRR:
-
Material removal rate (mm3/min)
- R a :
-
Surface roughness (μm)
- RSM:
-
Response surface methodology
- CCD:
-
Central composite design
- SEM:
-
Scanning electron microscope
- EDS:
-
Energy-dispersive spectroscopy
- XRD:
-
x-ray diffraction
- GRA:
-
Grey relation analysis
- GRG:
-
Grey relation coefficient
- GRC:
-
Grey relation grade
- ANOVA:
-
Analysis of variance
- SS:
-
Sum of square
- MS:
-
Mean square
- DOF:
-
Degree of freedom
- CI:
-
Confidence interval
References
J.M. Jani, M. Leary, A. Subic, and M.A. Gibson, A Review of Shape Memory Alloy Research, Applications and Opportunities, Mater. Des., 2014, 56, p 1078–1113
C. Velmurugan, V. Senthilkumar, S. Dinesh, and D. Arulkirubakaran, Machining of NiTi-Shape Memory Alloys—A Review, Mach. Sci. Technol., 2017, 22(3), p 355–401
H. Bisaria and P. Shandilya, Experimental Studies on Electrical Discharge Wire Cutting of Ni-Rich NiTi Shape Memory Alloy, Mater. Manuf. Process., 2017, 33(9), p 977–985
B. Ramachandran, C.H. Chen, P.C. Chang, Y.K. Kuo, C. Chen, and S.K. Wu, Thermal and Transport Properties of As-Grown Ni-Rich TiNi Shape Memory Alloys, Intermetallics, 2015, 60, p 79–85
H. Bisaria and P. Shandilya, The Machining Characteristics and Surface Integrity of Ni-Rich NiTi Shape Memory Alloy Using Wire Electric Discharge Machining, Proc. IMechE C J. Mech. Eng. Sci., 2018, https://doi.org/10.1177/0954406218763447
A. Rao, A.R. Srinivasa, and J.N. Reddy, Introduction to Shape Memory Alloys, Design of Shape Memory Alloy (SMA) Actuators, Springer, New York, 2015
P. Shandilya, H. Bisaria, and P.K. Jain, Parametric Study on Recast Layer During Electric Discharge Wire Cutting (EDWC) of Ni-Rich NiTi Shape Memory Alloy, J. Micro Manuf., 2018, 1(2), p 134–141
M. Manjaiah, S. Narendranath, and S. Basavarajappa, Review on Non-conventional Machining of Shape Memory Alloys, Trans. Nonferr. Met. Soc., 2014, 24, p 12–21
M. Karimzadeh, M.R. Aboutalebi, M.T. Salehi, S.M. Abbasi, and M. Morakabati, Adjustment of Aging Temperature for Reaching Superelasticity in Highly Ni-Rich Ti-51.5Ni NiTi Shape Memory Alloy, Mater. Manuf. Process., 2016, 31, p 1014–1021
K. Weinert, V. Petzoldt, and D. Kotter, Turning and Drilling of NiTi Shape Memory Alloys, CIRP Ann. Manuf. Technol., 2004, 53, p 65–68
Y. Guo, A. Klink, C. Fu, and J. Snyder, Machinability and Surface Integrity of Nitinol Shape Memory Alloy, CIRP Ann. Manuf. Technol., 2013, 62, p 83–86
S.F. Hsieh, S.L. Chen, H.C. Lin, M.H. Lin, and S.Y. Chiou, The Machining Characteristics and Shape Recovery Ability of Ti-Ni-X (X = Zr, Cr) Ternary Shape Memory Alloys Using the Wire Electro-discharge Machining, Int. J. Mach. Tools Manuf., 2009, 49, p 509–514
M.J. Haddad, F. Alihoseini, M. Hadi, M. Hadad, A.F. Tehrani, and A. Mohammadi, An Experimental Investigation of Cylindrical Wire Electrical Discharge Turning Process, Int. J. Adv. Manuf. Technol., 2010, 46, p 1119–1132
H. Bisaria and P. Shandilya, Experimental Investigation on Wire Electric Discharge Machining (WEDM) of Nimonic C-263 Superalloy, Mater. Manuf. Process., 2019, 34(1), p 83–92
K. Mouralova, J. Kovar, L. Klakurkova, and T. Prokes, Effect of Width of Kerf on Machining Accuracy and Subsurface Layer After WEDM, J. Mater. Eng. Perform., 2018, 27, p 1908. https://doi.org/10.1007/s11665-018-3239-4
A. Giridharan and G.L. Samuel, Analysis on the Effect of Discharge Energy on Machining Characteristics of Wire Electric Discharge Turning Process, Proc. IMechE B J. Eng. Manuf., 2015, 230(11), p 2064–2081
S. Bhattacharya, G.J. Abraham, A. Mishra, V. Kain, and G.K. Dey, Corrosion Behavior of Wire Electrical Discharge Machined Surfaces of P91 Steel, J. Mater. Eng. Perform., 2018, 27, p 4561. https://doi.org/10.1007/s11665-018-3558-5
M. Manjaiah, S. Narendranath, S. Basavarajappa, and V.N. Gaitonde, Effect of Electrode Material in Wire Electro Discharge Machining Characteristics of Ti50Ni50−xCux Shape Memory Alloy, Precis. Eng., 2015, 41, p 68–77
J.F. Liu, Y.B. Guo, T.M. Butler, and M.L. Weaver, Crystallography, Compositions, and Properties of White Layer by Wire Electrical Discharge Machining of Nitinol Shape Memory Alloy, Mater. Des., 2016, 109, p 1–9
G. Rajyalakshmi and P.V. Ramaiah, Multiple Process Parameter Optimization of Wire Electrical Discharge Machining on Inconel 825 Using Taguchi Grey Relational Analysis, Int. J. Adv. Manuf. Technol., 2013, 69, p 1249–1262
A. Saha and S.C. Mondal, Experimental Investigation and Modelling of WEDM Process for Machining Nano-structured Hardfacing Material, J. Braz. Soc. Mech. Sci. Eng., 2017, 39, p 3439–3455
H. Majumder, T.R. Paul, V. Dey, P. Dutta, and A. Saha, Use of PCA-Grey Analysis and RSM to Model Cutting Time and Surface Finish of Inconel 800 During Wire Electro Discharge Cutting, Measurement, 2017, 107, p 19–30
D.C. Montgomery, Design and Analysis of Experiments, 4th ed., Wiley, New York, 2001
H. Bisaria and P. Shandilya, Study on Effect of Machining Parameters on Performance Characteristics of Ni-Rich NiTi Shape Memory Alloy During Wire Electric Discharge Machining, Mater. Today Proc., 2018, 5, p 3316–3324
S. Narendranath, M. Manjaiah, S. Basavarajappa, and V.N. Gaitonde, Experimental Investigations on Performance Characteristics in Wire Electro Discharge Machining of Ti50Ni42.4Cu7.6 Shape Memory Alloy, Proc. IMechE B J. Eng. Manuf., 2013, 227(8), p 1180–1187
M. Manjaiah, S. Narendranath, S. Basavarajappa, and V.N. Gaitonde, Wire Electric Discharge Machining Characteristics of Titanium Nickel Shape Memory Alloy, Trans. Nonferr. Met. Soc., 2014, 24, p 3201–3209
N. Sharma, T. Raj, and K.K. Jangra, Parameter Optimization and Experimental Study on Wire Electrical Discharge Machining of Porous Ni40Ti60 Alloy, Proc. IMechE B J. Eng. Manuf., 2015, 231(6), p 956–970
M. Manjaiah, S. Narendranath, and S. Basavarajappa, Wire Electro Discharge Machining Performance of TiNiCu Shape Memory Alloy, Silicon, 2016, 8, p 467–475
S. Datta, A. Bandyopadhyay, and P.K. Pal, Solving Multi-criteria Optimization Problem in Submerged Arc Welding Consuming a Mixture of Fresh Flux and Fused Slag, Int. J. Adv. Manuf. Technol., 2008, 35, p 935–942
D. Ulutan and T. Ozel, Machining Induced Surface Integrity in Titanium and Nickel Alloys: A Review, Int. J. Mach. Tools Manuf., 2011, 51, p 250–280
A. Thakur and S. Gangopadhyay, State-of-the-Art in Surface Integrity in Machining of Nickel-Based Super Alloys, Int. J. Mach. Tools Manuf., 2016, 100, p 25–54
H. Bisaria and P. Shandilya, Study on Crater Depth During Material Removal in WEDC of Ni-Rich Nickel–Titanium Shape Memory Alloy, J Braz. Soc. Mech. Sci. Eng., 2019, 41, p 157. https://doi.org/10.1007/s40430-019-1655-5
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Bisaria, H., Shandilya, P. Surface Integrity of Ni-Rich NiTi Shape Memory Alloy at Optimized Level of Wire Electric Discharge Machining Parameters. J. of Materi Eng and Perform 28, 7663–7675 (2019). https://doi.org/10.1007/s11665-019-04477-2
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-019-04477-2