Exploring sustainable machining processes for nitinol shape memory alloy: a review of eco-friendly EDM and other techniques

Abstract The machining of Nitinol shape memory alloys (SMA) presents challenges because of their unique properties, such as high hardness, low thermal conductivity, and shape memory effect. Traditional machining methods, such as turning, milling, drilling, and grinding, result in significant materia...
Ausführliche Beschreibung

Abstract The machining of Nitinol shape memory alloys (SMA) presents challenges because of their unique properties, such as high hardness, low thermal conductivity, and shape memory effect. Traditional machining methods, such as turning, milling, drilling, and grinding, result in significant material wastage, excessive tool wear, and poor surface quality. Therefore, eco-friendly, cost-effective, efficient, and sustainable machining processes are required. Nonconventional methods, such as laser machining and electrochemical machining, also have limitations. Electrical discharge machining (EDM) has shown promise; however, environmental concerns exist. This review explores sustainable and eco-friendly EDM methods, including dry and near-dry EDM, for machining Nitinol SMA’s. The controllable parameters, environmental friendly dielectrics, and electrode materials affecting the process are discussed. Machining characteristics, such as material removal rate, tool wear rate, and surface roughness, are evaluated, and experimental design and optimization techniques for dry and near-dry EDM are reviewed. The findings suggest that these methods can effectively machine Nitinol SMA’s with improved surface quality and reduced tool wear while being environmentally friendly. The review concludes that utilizing bio-dielectrics, adopting dry or near-dry EDM processes, and incorporating conductive powders are effective strategies for mitigating environmental hazards, improving efficiency, and enhancing surface quality in EDM operations. They also highlight the promising potential of sustainable and eco-friendly EDM methods for future applications in Nitinol SMA machining, serving as a valuable resource for researchers, engineers, and industries seeking environmentally conscious machining solutions for challenging materials such as Nitinol SMAs. Ausführliche Beschreibung