Open Access
EDM machinability and surface roughness analysis of INCONEL 600 using graphite electrodes
(Springer, 2016) Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Luis Pérez, Carmelo Javier; Ingeniería; Ingeniaritza
Open Access
Surface roughness analysis on the dry turning of an Al-Cu alloy
(Elsevier, 2015) Torres Salcedo, Alexia; Puertas Arbizu, Ignacio; Luis Pérez, Carmelo Javier; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
Nowadays, surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered one of the most important parameter in Industry. In this present study, the influence of different machining parameters on surface roughness has been analyzed. All these parameters have been studied in terms of depth of cut (ap), feed rate (F), cutting speed (Vc) and tool radius (R). A 2030-T4 aluminium alloy has been selected. Moreover, Design of Experiments (DOE) techniques have been used to predict the surface quality in advance and to select the optimal turning conditions. The experimental results revealed that for dry turning operations and for the amplitude parameters, the most significant factor was the interaction effect between the depth of cut and the feed rate. In addition, for facing operations, the feed rate turned out to be the most statistically influential factor of all the surface roughness parameters.
Open Access
Study and optimization of the punching process of steel using the Johnson-Cook damage model
(MDPI, 2024) Claver Alba, Adrián; Hernández Acosta, Andrea; Barba Areso, Eneko; Fuertes Bonel, Juan Pablo; Torres Salcedo, Alexia; García Lorente, José Antonio; Luri Irigoyen, Rodrigo; Salcedo Pérez, Daniel; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
Sheet metal forming processes are widely used in applications such as those in the automotive or aerospace industries. Among them, punching is of great interest due to its high productivity and low operating cost. However, it is necessary to optimize these processes and adjust their parameters, such as clearance, shear force or tool geometry, to obtain the best finishes and minimize crack generation. Thus, the main objective of this research work is to optimize the punching process to achieve parts that do not require subsequent processes, such as deburring, by controlling the properties of the starting materials and with the help of tools such as design of experiments and simulations. In the present study, tensile tests were performed on three steels with different compositions and three sample geometries. The information obtained from these tests has allowed us to determine the parameters of the Johnson-Cook damage criteria. Moreover, punching was performed on real parts and compared with simulations to analyze the percentage of burnish surface. The results obtained show that the methodology used was correct and that it can be extrapolated to other types of die-cutting processes by reducing the percentage of surface fractures and predicting the appearance of cracks. Furthermore, it was observed that clearance has a greater influence than processing speed, while the minimum percentage of the burnish area was observed for the minimum values of clearance.
Open Access
CES EduPack: una herramienta informática para motivar e inspirar el conocimiento de las aleaciones metálicas en alumnos de Ingeniería
(Dykinson, 2021) Armañanzas Goñi, Javier; Torres Salcedo, Alexia; Fuertes Bonel, Juan Pablo; Rivero Fuente, Pedro J.; Ingeniería; Ingeniaritza
La Ingeniería de los Materiales se puede definir como la rama de la Ciencia que estudia la composición y la estructura de los materiales, así como de la forma en que estos factores se relacionan con sus propiedades o su comportamiento en servicio. Debido a ello, la base de la Ingeniería de los Materiales se basa en establecer una relación directa entre la estructura (bien cristalina o amorfa) y su correspondencia con las propiedades finales de distinta índole tales como físicas, mecánicas, ópticas, químicas o térmicas. Este conocimiento resulta de gran interés por tres motivos principales. El primero es que te permite conocer las características de los materiales y te sirve de ayuda para el estudio de aplicaciones específicas. En segundo lugar, se puede conocer en mayor medida los efectos asociados a los distintos procesos de fabricación y relacionarlos con una microestructura específica. Por último, en tercer lugar, permite a un Ingeniero saber utilizar el material más adecuado en función de las condiciones de servicio en un campo de aplicación determinado.
Open Access
EDM machinability and surface roughness analysis of TiB2 using copper electrodes
(Elsevier, 2017-01-05) Torres Salcedo, Alexia; Luis Pérez, Carmelo Javier; Puertas Arbizu, Ignacio; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
Titanium diboride (TiB2) is a sintered ceramic material which has a high industrial interest due to its excellent mechanical properties, such as immense hardness, elastic modulus, and abrasion resistance. Unlike most ceramics, this material can be machined by using an electrical discharge machining (EDM) process because of its good thermal and electrical conductivity. In this present study the applicability of an EDM process for manufacturing titanium diboride is analysed. To do that, the influence of EDM parameters is studied on three of the most important technological characteristics in EDM: material removal rate (MRR), electrode wear (EW) and surface roughness (Ra). Results confirm that the most influential factor on MRR and Ra is the current intensity whereas in the case of EW, it is the pulse time. Additionally, the control of these parameters allows technological tables to be obtained in order to determine the optimum operating conditions. Such technological tables exist for the case of steels but they do not exist for TiB2, in which the optimal conditions are to be determined experimentally.
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
Design and experimentation of a hydrokinetic turbine for electricity generation in closed pipes
(World Scientific and Engineering Academy and Society, 2024) Armañanzas Goñi, Javier; Alcalá, Marina; Fuertes Bonel, Juan Pablo; León Iriarte, Javier; Torres Salcedo, Alexia; Gil Liberal, Miguel; Ingeniería; Ingeniaritza
In the present research work, a device for electrical energy generation to be used in water pipelines has been designed, simulated, and tested. To achieve this, a study of the most influential parameters involved in the experiment has been carried out and both, the turbine model and the geometry of the experimental test pipe, have been selected through CFD simulations. Next, the Design of Experiments (DOE) has been used to obtain the configuration with a higher energy extraction from running water. Finally, the turbine and the test pipe section have been manufactured by 3D printing and the experimental tests have been carried out with the optimal configuration to validate the results obtained in the CFD simulations. To simulate the exchange of energy between the water and the turbine, the CFD software SIMULIA XFlow has been used.
Open Access
Elemento de refrigeración de material cerámico electroconductor
(2024) Luis Pérez, Carmelo Javier; Puertas Arbizu, Ignacio; Torres Salcedo, Alexia; Ingeniería; Ingeniaritza
Elemento de refrigeración de material cerámico electroconductor que comprende un cuerpo (1) con al menos un orificio (2) pasante y/o al menos una ranura (3) pasante, configurados para el paso de un fluido de refrigeración, donde al menos un orificio (2) y/o la al menos una ranura (3) están fabricados mediante electroerosión por penetración sobre el cuerpo (1) de material cerámico electroconductor.
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.