Open Access
Análisis y modelización de los parámetros de influencia en la electroerosión por penetración de materiales de baja mecanizabilidad
(2016) Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Luis Pérez, Carmelo Javier; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
En la presente tesis doctoral se realiza un análisis y una modelización de los parámetros de mayor influencia en la electroerosión por penetración de tres materiales de baja mecanizabilidad. En concreto, el estudio se centra en la aleación Inconel® 600 (Special Metals Corporation) y en las cerámicas diboruro de titanio (TiB2) y carburo de silicio infiltrado con silicio (SiSiC). Actualmente, estos materiales resultan de gran interés para aplicaciones industriales en los sectores aeronáutico, nuclear y automotriz, debido a la combinación de buenas propiedades mecánicas, resistencia a la corrosión y extremada dureza a altas temperaturas. Para llevar a cabo dicho estudio, se emplean metodologías basadas en el Diseño de Experimentos (DOE), para la planificación y selección de los valores de los parámetros, así como para la obtención de modelos matemáticos que permitan predecir las condiciones óptimas de mecanizado. Asimismo, se determinan tablas tecnológicas, para dichos materiales, en función de los parámetros de diseño: intensidad, tiempo de impulso y rendimiento, en los rangos de estudio considerados. A partir de estas tablas, es posible predecir la obtención de una determinada rugosidad superficial en base a dos estrategias de mecanizado consistentes en maximizar la tasa de eliminación de material, o bien, en minimizar el desgaste del electrodo. Para la generación de las tablas tecnológicas, se emplean los valores experimentales y, en aquellos casos donde no sea posible disponer de datos experimentales, se emplean métodos de optimización no lineal para predecir dichos valores, utilizando los modelos matemáticos generados, en base a los resultados experimentales. Además, se hace uso de microscopía electrónica de barrido (SEM), con objeto de obtener información relativa a la topografía de las superficies resultantes tras la EDM. Finalmente, se propone un nuevo parámetro denominado ‘densidad de energía’ con el fin de profundizar en el estudio del proceso de EDM.
Open Access
Optimization and modeling of ZrB2 ceramic processing by EDM for high-performance industrial applications
(Elsevier, 2025-04-11) Luis Pérez, Carmelo Javier; Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
This study investigates the Electrical Discharge Machining (EDM) of zirconium diboride (ZrB2), a novel conductive ceramic with exceptional properties, including high temperature resistance, excellent thermal conductivity, and remarkable hardness. These properties make ZrB2 highly suitable for extreme environments, such as aerospace and nuclear applications. To the best of our knowledge, no comprehensive studies have addressed the manufacturing of ZrB2 parts by EDM, positioning this research as a cutting-edge contribution. Two electrode materials, graphite (C) and copper-graphite (Cu–C), were used to analyze the material removal rate (MRR) and surface roughness (Ra) as functions of current intensity (I), pulse time (ti), and duty cycle (η). Multiple Linear Regression (MLR) and Artificial Neural Networks (ANN) were used to model the response variables. While MLR was effective for MRR (R2 > 0.9), ANN outperformed it in predicting Ra, especially for Cu–C electrodes (R2 = 0.9366 vs. 0.3847 for MLR). Current intensity was the most influential parameter for MRR, while pulse time significantly affected Ra. Residual analysis confirmed ANN superior accuracy for Ra, with residuals below ±1 vs. ±2 for MLR. The study culminated in the successful EDM manufacture of a ZrB2 hexagonal nut, employing optimized parameters (I = 6 A, ti = 50 μs, η = 0.3, for the C electrode) derived using ANN models and particle swarm optimization. This result demonstrates the EDM process ability to produce high-precision components with complex geometries, showcasing its versatility and industrial potential. Therefore, this study broadens the understanding of ZrB2 machinability and expands its applications in advanced technologies.
Open Access
Spacing roughness parameters analysis on the EDM of Inconel (R) 600 alloy
(Elsevier, 2017) Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Luis Pérez, Carmelo Javier; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
Many research studies may be found regarding the measurement of surface roughness parameters. Most of them are focused on amplitude parameters as they are the most commonly used in industry, while little research has been found on the spacing ones. Spacing roughness parameters measure the horizontal characteristics of the surface deviations. In this present study, the influence of current intensity, pulse time and duty cycle on spacing roughness parameters Sm and Pc has been analyzed. Design of experiments techniques are used in order to both model and predict the most influential factors by using a small number of experiments. Current intensity of 2 A, pulse time of 25 mu s and duty cycle of 0.5 are selected as the best machining conditions in order to obtain the lowest surface roughness.
Open Access
Analytical modelling of energy density and optimization of the EDM machining parameters of Inconel 600
(MDPI, 2017) Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Luis Pérez, Carmelo Javier; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
In this present research work, a new modelling of energy density in EDM (Electrical Discharge Machining) is proposed. Energy density can be defined as the amount of energy needed to get a unit volume of material removed, and for its modelling, the whole EDM process has been taken into account. This new definition lets us quantify the energy density that is being absorbed by the workpiece and the electrode. Results are compared to those obtained by die sinking EDM in an Inconel ®600 alloy using Cu-C electrodes. Currently, this material is of great interest for industrial applications in the nuclear, aeronautical and chemical sectors, due to their combinations of good mechanical properties, corrosion resistance and extreme hardness at very high temperatures. The experimental results confirm that the use of negative polarity leads to a higher material removal rate, higher electrode wear and higher surface roughness. Moreover, the optimal condition to obtain a maximum MRR (Material Removal Rate) of 30.49 mm3/min was: 8 A, 100 µs and 0.6, respectively, for the current intensity, pulse time and duty cycle.
Open Access
Spacing roughness parameters analysis on the EDM of TiB2
(Elsevier, 2017) Torres Salcedo, Alexia; Luis Pérez, Carmelo Javier; Puertas Arbizu, Ignacio; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
Titanium diboride (TiB2) is a novel sintered ceramic material which has attracted a great deal of interest because of its excellent mechanical properties, wear resistance and chemical resistance. At present, this ceramic is used in specialized applications in such areas as impact resistant armor, cutting tools, crucibles and wear resistant coatings. In this present research work, effects of current intensity, pulse time and duty cycle on the spacing roughness parameters Sm and Pc have been studied. In addition, statistical tools based on the design of experiments as well as multiple linear regression techniques have been used. Experimental results suggest that the optimal conditions to obtain a minimum Sm of 52.60 gm and a maximum Pc of 190.60 cm(-1) were: 2 A, 5 mu s and 0.4, respectively, for current intensity, pulse time and duty cycle.