Effect of Drilling Conditions on Microwave-Metal Discharge during Microwave Drilling of Stainless Steel

Abstract:

Processing of metallic materials using microwave energy offer benefits of time compression and energy saving during applications such as sintering, casting, melting, joining and cladding. However, use of microwave energy is uncommon for machining of metallic materials because of high reflectivity. The present work aims to study microwave-metal (MW-m) discharge-induced plasma channel (PC) characteristics during microwave drilling of thin stainless steel (SS) sheet (0.6 mm) at 2.45 GHz. Experimental trials inside two different microwave applicators A1 and A2 were monitored and recorded. The images of the plasma channel generated in both the microwave applicators were obtained at different time intervals to analyze the plasma channel diameter (PCD). Experimental results revealed that variation in the microwave power significantly affects the dimension of plasma channel generated in the tool-work gap and heat affected zone (HAZ) formed around the drilling zone. Reduction in microwave drilling time of approximately 80% was observed at 3 kW power compared to drilling time at 0.7 kW power. The HAZ observed in the samples drilled at 0.7 kW was significantly higher than the HAZ observed at 3 kW owing to higher drilling time of samples at 0.7 kW.

• Periodical: Applied Mechanics and Materials (Volume 895)
• Pages: 253-258
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.895.253
• Online since: November 2019
• Authors: Anurag Singh*, Apurbba Kumar Sharma
• Keywords: Microwave Drilling, Microwave-Metal (MW-m) Discharge, Plasma Channel (PC), Plasma Channel Diameter (PCD)

References

[1] J. Sun, W. Wang, Q. Yue, C. Ma, J. Zhang, X. Zhao, Z Song, Review on microwave–metal discharges and their applications in energy and industrial processes, Applied Energy. 175 (2016) 141-157.

DOI: 10.1016/j.apenergy.2016.04.091

[2] J. Sun, W. Wang, Q. Yue, Review on microwave-matter interaction fundamentals and efficient microwave-associated heating strategies, Materials. 9(4) (2016) 231.

DOI: 10.3390/ma9040231

[3] W. Wang, L. Fu, J. Sun, S. Grimes, Y. Mao, X. Zhao, Z. Song, Experimental study of microwave-induced discharge and mechanism analysis based on spectrum acquisition, IEEE Transactions on Plasma Science. 45(8) (2017) 2235-2242.

DOI: 10.1109/tps.2017.2715800

[4] W. Wang, Z. Liu, J. Sun, Q. Ma, C. Ma, Y. Zhang, Experimental study on the heating effects of microwave discharge caused by metals, AIChE Journal. 58(12) (2012) 3852-3857.

DOI: 10.1002/aic.13766

[5] W. Chen, B. Gutmann, C. O. Kappe, Characterization of Microwave‐Induced Electric Discharge Phenomena in Metal–Solvent Mixtures, ChemistryOpen. 1(1) (2012) 39-48.

DOI: 10.1002/open.201100013

[6] A. G. Whittaker, D. M. P. Mingos, Arcing and other microwave characteristics of metal powders in liquid systems, Journal of the Chemical Society. (9) (2000) 1521-1526.

DOI: 10.1039/b000462f

[7] A. G. Whittaker, D. M. P. Mingos, Synthetic reactions using metal powders under microwave irradiation, Journal of the Chemical Society. (21) (2002) 3967-3970.

DOI: 10.1039/b206557f

[8] J. Sun, W. L. Wang, C. Y. Ma, Q. Y. Yue, Study on the promotion effect of microwave-metal discharge on the microwave pyrolysis of electronic waste, In Advanced Materials Research. 1088 (2015) 843-847.

DOI: 10.4028/www.scientific.net/amr.1088.843

[9] J. Sun, W. Wang, Z. Liu, Q. Ma, C. Zhao, C. Ma, Kinetic study of the pyrolysis of waste printed circuit boards subject to conventional and microwave heating, Energies. 5(9) (2012) 3295-3306.

DOI: 10.3390/en5093295

[10] H. B. Al-Wakeel, Z. A. Karim, H. H. Al-Kayiem, Optimizing electro-thermo Helds for soot oxidation using microwave heating and metal, In IOP Conference Series: Materials Science and Engineering. 78 (1) (2015) 012018.

DOI: 10.1088/1757-899x/78/1/012018

[11] J. G. Titto, A. K. Sharma, P. Kumar, A feasibility study on drilling of metals through microwave heating, i-Manager's Journal on Mechanical Engineering. 2(2) (2012) 1.

[12] T. J. George, A. K. Sharma, P. Kumar, R. Kumar, S. Das, Microwave Drilling: Future Possibilities and Challenges Based on Experimental Studies, In International Conference on Emerging Trends in Manufacturing Technology, Toc H Institute of Science & Technology. Kerela (2012).

[13] N. K. Lautre, A. K. Sharma, P. Kumar, Distortions in hole and tool during microwave drilling of perspex in a customized applicator, In Microwave Symposium (IMS). (2014)1-3.

DOI: 10.1109/mwsym.2014.6848410

[14] N. K. Lautre, A. K. Sharma, P. Kumar, S. Das, Performance of different drill bits in microwave assisted drilling, International Journal of Mechanical Engineering and Robotics Research. 1(1) (2014) 22-29.

[15] N. K. Lautre, A. K. Sharma, P. Kumar, S. Das, Microwave drilling with Litz wire using a domestic applicator, Bonfring International Journal of Industrial Engineering and Management Science. 4(3) (2014) 125.

DOI: 10.9756/bijiems.6053

[16] N. K. Lautre, A. K. Sharma, P. Kumar, S. Das, A photoelasticity approach for characterization of defects in microwave drilling of soda lime glass, Journal of Materials Processing Technology. 225 (2015) 151-161.

DOI: 10.1016/j.jmatprotec.2015.05.026

[17] N. K. Lautre, A. K. Sharma, P. Kumar, S. Das, A simulation approach to material removal in microwave drilling of soda lime glass at 2.45 GHz, Applied Physics A. 120(4) (2015) 1261-1274.

DOI: 10.1007/s00339-015-9370-2

[18] N. K. Lautre, A. K. Sharma, P. Kumar, S. Das, On Crack Control Strategy in Near-Field Microwave Drilling of Soda Lime Glass Using Precursors, Journal of Thermal Science and Engineering Applications. 7(4) (2015) 041001.

DOI: 10.1115/1.4030478

[19] G. Kumar, A. K. Sharma, Role of dielectric fluid and concentrator material in microwave drilling of borosilicate glass, Journal of Manufacturing Processes. 33 (2018)184-193.

DOI: 10.1016/j.jmapro.2018.05.010