3.

5 Effect of machining parameters on recast layer

Mots principaux :

Machining parameters Recast

layer
Wire electro-discharge machining (WEDM) Dielectric fluid
Solidified layer White
layer Trial number 19
Trial number 15
Thickness
MRR (Material Removal Rate) Wire
feed
Heat generation Spark
gap Molten material
Surface roughness Porous
structure Oxide recast
layer Bony growth
Implants
Human body
Adhesion
Implantation performance Ti-Ni
implants

Mots secondaires :

Rapid heating
Quenching Geta
deposition
Fig. 7 (figure reference)
Increased MRR Enhanced
splashing
Human body compatibility Porous
and thick layer
Oxide recast layer benefits for implants

• Effect of machining parameters on micro-hardness Mots

principaux :

Machining parameters
Micro-hardness
WEDM (Wire Electro-Discharge Machining)
Surface integrity
Ti-Ni (Titanium-Nickel) Trial
number 15
Trial number 19
 Fig. 83 (figure reference) Micro
Vickers hardness tester Heat-affected
recast layer
Depth of the effective recast layer Load
Indentation
TINI SMA (Titanium-Nickel Shape Memory Alloy)
Resolidification
Molten materials
Workpiece Electrode
T10 NITIO (Titanium-Nickel-Titanium Oxide) CuO
(Copper Oxide)
HV (Vickers hardness) Heat-
affected zone
Biocompatibility
Biomedical orthopedic applications
Mots secondaires :
Removal of materials Higher
temperature Surface
generated 400x
magnification Recast layer
formation Applied load of
50g Indentation for 15s
Lengths of diagonals

Un-machined surface
T10 NITIO and CuO as electrode materials Mean
value of Vickers hardness
Heat-affected zone depth Substantial
difference in hardness
Investigating the effect of surface micro-hardness Biomedical
orthopedic applications Biocompatibility assessment

• Effect of residual stresses

Mots principaux :
Residual stresses Phase
formation White layer
Retained austenite
Severely distorted martensite Quantitatively
Qualitatively
Correlation Micro
cracks Fracture
strength
 Carbon ingredients Non-
homogeneity XRD
analysis
DB discover (model) Bruker
(manufacturer) Cuk, X-ray
radiation Wave length
Beam diameter
Machined sample
Fig. 9 (figure reference)
Surface
Peak
Thickness of the white layer Heat-
affected zone
Optical microscope
Structural changes Solid
state
Relaxed Negative
value
Compressive residual stresses Equilibrated
Maximum peak residual stresses Orthopedic
implant
Process parameters Pulse
on time

Pulse of time
Spark gap set voltage Wire
feed
Wire tension
Dynamic compression plate
Mots secondaires :
Role Build-
up
Retained austenite formation Distorted
martensite formation Microstructure
Machined surface Trial
number 15
Trial number 19
Excessive carbon ingredients Non-
uniformity
Higher amount of residual stresses XRD
analysis details
Surface integrity study Suitability for
orthopedic implant
 Process parameters for dynamic compression plate manufacture Pulse on time
unit
Spark gap set voltage Wire
feed rate
Wire tension unit
Comparison between trial numbers
Orthopedic implant manufacturing suitability conclusion

• Orthopedic application (dynamic compression plate)

Mots principaux :

Orthopedic application
Dynamic compression plate (DCP) Metallic
plate
Internal fixation Bone
fractures Dynamic
force Implant design
Ti-Ni (Titanium-Nickel)
Biomedical material Optimized
parameters Trial number 19
Physical properties Mechanical
properties Table 4 (table
reference)
CNC universal testing machine Model
Unitech 1650-TS
Fuel inumanus and engiwen, India Elastic
modulus
Load-bearing bone
Resorption Complications
Bone fracture
Loosening of implant
Young's modulus
B-phase (TIN)
Panectaid phase
Cortical bone GP
(Gigapascal)
Biomedical alloys
SS316L

Mots secondaires :

Application in orthopedics Exerting

dynamic force Adaptation of implant
design Human application requirements
 Biomedical material recommendation Machining
with optimized parameters Physical and mechanical
properties details CNC universal testing machine
details

Elastic modulus considerations Load-

bearing bone challenges Resorption
consequences Complications in bone
health Young's modulus comparison B-
phase characteristics Panectaid phase
significance
Lower Young's modulus benefits Comparison
with other biomedical alloys Ti-Ni's unique
properties
SS316L properties comparison Mechanical
testing and measurement Reference to Table 4
Trial number 19 as the preferred choice

• Manufacturing process of DCP from Ti-Ni SMAS

• Model mesh design and analysis in ANSYS
Mots principaux :

Manufacturing process
DCP (Dynamic Compression Plate)
Ti-Ni SMAS (Titanium-Nickel Shape Memory Alloy) Model
mesh design
Analysis in ANSYS
Fig. 11 (figure reference) Finite
element model Thickness
FUSION 360
FE analysis Assumptions
Residual stresses Thermal
contraction
Microstructural changes
Induced stress Discharging
stage
High-temperature plasma channel
Maximum stress
MPa (Megapascal) Yield
strength Material
Table 4 (table reference)
Suitable

Mots secondaires :
 ANSYS R15.0
Brick 8-node elements Nodes
Analysis details Assumption
explanations
Maximum stress measurement Thickness
of the DCP plate Material yield strength
Table 4 reference
Material suitability conclusion
Thermal contraction effects
Microstructural changes considerations Induced
stress during heating
Melting and softening in a high-temperature plasma channel Material
properties
Comparison with yield strength

Suitability determination
Megapascal as a unit of stress measurement

• The shape recovery ability near WEDMed surfaces of TI-NI SMA

Mots principaux :

Shape recovery ability WEDMed

surfaces
Ti-Ni SMA (Titanium-Nickel Shape Memory Alloy)
Bending stiffness
Three-point bending test
Model-Unitech 1650-15
Fuel Instruments and Engineers, India ISO 150
9585:1990(E)
Rater-filled chamber Shape
memory effect
Austenite finish temperature
Thermostat device
Table 5 (table reference)
Measured shape recovery
Specimen thickness
Heat-affected zone As-
annealed alloy WEDMed
alloy
Annealed after WEDMed alloy
Perfect shape recovery Bending
strains
Wire electro discharge machining
Annealing
Must
Mots secondaires :

Shape recovery determination Testing

near WEDMed surfaces Three-point
bending test details
Testing machine model and manufacturer ISO
standard reference
Water-filled chamber details
One-way shape memory effect induction Austenite
finish temperature control Thermostat device usage
Thickness for shape memory effect test Comparison with
heat-affected zone thickness Results presentation in Table 5

Comparison among alloy conditions Bending strain

levels
WEDMed alloy characteristics Annealing
process significance Recovery of shape
memory effect Importance of annealing after
WEDM
Electro discharge machining impact on shape recovery Shape recovery
at different bending strains
Must for shape memory effect recovery after WEDM

• Procem of marufornaring of DCP

Mots principaux :

Process of manufacturing DCP

Ti-Ni SMA (Titanium-Nickel Shape Memory Alloy) Wire
electro-discharge machining (WEDM) Electro-discharge
machining
Electropolishing Heat
treatment Anodizing
Experimental setup
Fig. 12 (figure reference)
Workpiece
Flat surface
Front and back radii Holes
drilling Electrode
Elliptical holes WEDM
parameters Pulse on time
Pulse off time
Spark gap set voltage Wire
feed
 Wire tension Electropolishing
benefits External magnetic field
Microtopography
Microroughness
Surface area Corrosion
resistance Biocompatibility
Cleanability
Heat treatment (Annealing) Ni
release
Oxide layers Commercial
implants Protective oxide
coating Corrosion
minimization Human body
Fig. 13 (figure reference)

Mots secondaires :

Steps in DCP manufacturing

Ti-Ni SMA usage in DCP

Machining techniques Electrode
material Elliptical hole
production
Reference for WEDM parameters
Electropolishing process details Magnetic field
impact on electropolishing Micro and nano scale
considerations Corrosion resistance enhancement
Benefits of electropolishing treatment Reliable
barrier creation
Ni release prevention
Shape memory effect maintenance Heat
treatment role in manufacturing Oxide layer
thickness
Beneficial effects for biomedical implants
Commercial implant standards Protective coating
importance
Corrosion minimization inside the human body Visual
representation of manufactured DCP (Fig. 13)

• Conclusions
Mots principaux :

Conclusions
Process parameters Pulse
on time
 Pulse off time
Spark gap set voltage Wire
feed
Wire tension
WEDM performance characteristics MRR
(Material Removal Rate)
SK (Surface Roughness) Ti-Ni
shape memory alloy
GRA (Grey Relational Analysis)
Optimization
Quality improvement
Experimentation
Micrographs
Recast layer
Microhardness
Residual stresses
Shape recovery ability EDS
analysis Metallurgical
changes Orthopedic implant
Ti (Titanium)
SS316L (Stainless Steel 316L)
Young's modulus
Smooth surface finish
Deposition of material
Heat-affected zone (White Layer)
Hardness
EDS analysis results
Copper and zinc presence
Wire electrode material deposition Carbon
content
WEDM process parameters for dynamic compression plate Heat
treatment (Annealing)
Retention of shape memory effect
Bending strains

Mots secondaires :

Investigation of process parameters Multi-

objective optimization
GRA application in initial trial
Quality verification
Experimental verification in predicted trial
Comparison of characteristics Microstructure
analysis
Orthopedic implant material suitability
Comparison with other implant materials Grey
Relational Analysis details
Increase in wire feed impact on characteristics EDS
analysis for metallurgical changes
Elemental migration from wire electrode Carbon
content variation with wire feed WEDM process
parameter details
Manufacturing of dynamic compression plate
Role of heat treatment in shape memory retention
High bending strains impact on shape memory effect.