Effect of the physicochemical properties and structure of tool electrode materials on their erosion resistance during electric - contact machining

1980 ◽  
Vol 19 (11) ◽  
pp. 783-787
Author(s):  
A. B. Borisov ◽  
A. D. Verkhoturov ◽  
M. S. Koval'chenko
Keyword(s):  
Physicochemical Properties ◽  
Electrode Materials ◽  
Erosion Resistance ◽  
Tool Electrode ◽  
Electric Contact

scholarly journals Experimental study on high-efficiency DC short electric arc milling of titanium alloy Ti6Al4V

2021 ◽  
Author(s):  
Zongjie Zhou ◽  
Kai Liu ◽  
Yan Xu ◽  
Jianping Zhou ◽  
Lizhong Wang
Keyword(s):  
Titanium Alloy ◽  
Electrode Material ◽  
Material Removal ◽  
Electrode Materials ◽  
Arc Discharge ◽  
Specific Energy Consumption ◽  
Base Material ◽  
Electric Arc ◽  
Tool Electrode ◽  
Q235 Steel

Abstract Short electric arc milling (SEAM) is an efficient electrical discharge machining method, especially for the efficient removal of difficult-to-machine conductive materials with high hardness, high toughness, and wear resistance. In this study, titanium alloy Ti–6Al–4V is used as the research object to conduct machining experiments. The material removal mechanism of SEAM technology is studied using a DC power supply and different tool electrode materials (copper, graphite, Q235 steel, and titanium). The energy distribution of the discharge gap is analyzed using a data acquisition system and a high-speed camera. The arc is found to move with the spindle rotation in the process of arc discharge, and multi-point discharge occurs in the process of single-arc discharge. The voltage and current waveforms and the radius of the etched particles during the experiment were counted, the material removal rate (MRR) and relative tool wear rate (RTWR) are calculated, and the surface and cross-section micromorphology and hardness are analyzed. The experimental results show that when the electrode material is graphite, the maximum feed rate is 650 mm/min, the MRR can reach 17268 mm3/min, the ideal maximum MRR is more than 65000 mm3/min, and the RTWR is only 1.27%. When the electrode material is Q235 steel, the minimum surface roughness is 35.04 µm, and this material has good stability under different input voltages. When the electrode material is copper, the hardness of the resolidified layer is close to that of the base material, which is beneficial for further processing. The lowest specific energy consumption is 18.26 kJ/cm3 when titanium is used as the electrode material.

Effect of Process Parameters in Electric Discharge Machining of Ti-6Al–4V Alloy by Three Different Tool Electrode Materials

2012 ◽  
Vol 488-489 ◽  
pp. 876-880 ◽  
Author(s):  
Manoj Kumar Kuttuboina ◽  
A. Uthirapathi ◽  
Singaravelu D. Lenin
Keyword(s):  
Process Parameters ◽  
Electrode Material ◽  
Electrode Materials ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Good Surface ◽  
Pulse On Time

The effect of process parameters namely peak current, pulse on time and flushing pressure on electrical discharge machining (EDM) of titanium alloy (Ti–6Al–4V) were investigated by using three different tool electrode materials namely copper, brass, and aluminium. Kerosene is used as dielectric. The process parameters for machining Ti6Al4V are varied at three levels by using Taguchi's orthogonal array table. The responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) are measured and the most significant parameter was confirmed by ANOVA (Analysis Of Variance). The test result shows that copper electrode material possesses higher MRR, less TWR as compared to brass and aluminium. Brass and copper tools has good surface finish as compared with aluminium. The finest electrode material for machining of Ti6Al4V alpha beta alloy in EDM process was in the order of copper, brass and aluminium.

scholarly journals Influence of Different Tool Electrode Materials on Electrochemical Discharge Machining Performances

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1077
Author(s):  
Islam Md. Rashedul ◽  
Yan Zhang ◽  
Kebing Zhou ◽  
Guoqian Wang ◽  
Tianpeng Xi ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Electrical Conductivity ◽  
Electrode Materials ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Channels

Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.

scholarly journals NOVEL NON-AQUEOUS ELECTROLYTES BASED ON COORDINATION BORON COMPOUNDS

2021 ◽  
Vol 87 (3) ◽  
pp. 41-60
Author(s):  
Viktor Diamant
Keyword(s):  
Electrical Conductivity ◽  
Physicochemical Properties ◽  
Alkali Metals ◽  
Electrode Materials ◽  
Electrochemical Stability ◽  
Potential Range ◽  
Protective Film ◽  
Chelate Ligand ◽  
Power Sources ◽  
Advantages And Disadvantages

The review provides a classification of electrolytes for modern chemical power sources, supercapacitors, sodium and lithium-ion batteries depending on changes in the physicochemical properties of salts and the products of their interaction with the solvent. A comparative analysis of physicochemical properties of salts depending on the structure of the cation and anion, and the influence of these properties on the properties of final solutions of electrolytes on the example of different classes of ionic liquids and chelatoborates of alkali metals and ammonium was conducted. The dependence of the physicochemical properties of electrolytes (solubility, electrical conductivity of solutions and the range of potentials of electrochemical stability) on the nature of the chelate ligand, electron donor and electroacceptor substituents in the bis (chelate) borate anion is analyzed. The electrical conductivity of salt solutions and ranges of potentials of electrochemical stability of the corresponding electrolytes containing other anions and used for a long time in chemical current sources are carried out. The advantages and disadvantages of using liquid electrolytes compared to solid and polymer electrolytes in terms of similarity of their structures have been detected. It is shown that the nature of the chelate ligand, electro-donor and electro-acceptor substituents in the bis (chelato) borate anion is an important factor in regulating the interaction with aprotic dipolar solvents. Mixed salts with two different chelate ligands typically combine the best characteristics of the corresponding monochelate compounds, but the methods for their preparation and purification are technologically significantly more complex compared to monochelate compounds. The analysis of the mechanism of formation of a protective film on a surface of electrode materials, dependence of potential on its formation and on the chemical nature of ligands is made. It is noted that bis (chelato) borate salts are more environmentally friendly compared to fluorine-containing complex salts. Emphasis is placed on the physicochemical properties of solutions of the most promising chelatoborate salts for use in lithium and sodium ion batteries, supercapacitors and electrolytic capacitors, and it is shown that bis (oxalate) borates and bis (salicylate gold) borates occupy ) borates in terms of electrical conductivity, solubility and potential range of electrochemical stability.

Effect of surface roughness of tool electrode materials in ECDM performance

2010 ◽  
Vol 50 (12) ◽  
pp. 1088-1096 ◽  
Author(s):  
Cheng-Kuang Yang ◽  
Chih-Ping Cheng ◽  
Chao-Chuang Mai ◽  
A. Cheng Wang ◽  
Jung-Chou Hung ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrode Materials ◽  
Tool Electrode ◽  
Effect Of Surface

Physicochemical properties of electrode materials based on substituted yttrium manganite

2005 ◽  
Vol 41 (3) ◽  
pp. 259-264
Author(s):  
L. A. Tikhonova ◽  
A. F. Poluyan ◽  
A. N. Glushko ◽  
A. A. Vecher ◽  
D. V. Znosok
Keyword(s):  
Physicochemical Properties ◽  
Electrode Materials

scholarly journals Prediction and experimental verification of erosion resistance of gas switch electrode materials

AIP Advances ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 055206
Author(s):  
Cheng Luo ◽  
Peitian Cong ◽  
Tianyang Zhang ◽  
Xiangli Zhong ◽  
Weixi Luo
Keyword(s):  
Experimental Verification ◽  
Electrode Materials ◽  
Erosion Resistance ◽  
Gas Switch

scholarly journals Major Developments in EDM Surface Alloying using Composite Material Tool Electrode

2019 ◽  
Vol 8 (12) ◽  
pp. 4585-4587
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Heat ◽  
Stir Casting ◽  
Tool Electrode ◽  
Casting Technique ◽  
Engineering Materials ◽  
Lower Tool

Electric Discharge alloying/Coating (EDC) is an emerging field for the surface modification of advanced engineering materials like tool steel, high heat resistance alloy, titanium alloy etc. The advanced engineering materials have good mechanical properties and are used for the engineering applications like dies, aerospace, and automotives. To treat these difficult-to-machine advanced engineering materials with new challenges, numerous advancements in electrical discharge machining (EDM) processes have been carried out. Electrode materials for EDM are usually made up of copper, and its alloys. Proper selection with composition of electrode materials are required to avoid cracks, residual stresses etc during or after Electrical Discharge Machining and at the same time to have better surface finish and material removal rate and lower tool wear rate of the electrode. Further electrodes can be prepared by different methods like powder metallurgy, stir casting technique etc. This paper presents the brief details of effect of different electrodes on the surface and machining characteristics.

Micro EDM Deposition by Using Brass Wire Electrode in Air

2005 ◽  
Author(s):  
Guohui Cao ◽  
Guanxin Chi ◽  
Baidong Jin ◽  
Zhenlong Wang ◽  
Wansheng Zhao
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Process Technology ◽  
Workpiece Surface ◽  
Micro Electrical Discharge Machining ◽  
Original Metal ◽  
Brass Wire

Proposed a new process technology of micro electrical discharge machining (EDM) beyond the traditional EDM concept. This method can deposit the brass wire tool electrode on the workpiece surface by pulse discharges between anode and cathode in air. At first, the basic machining parameters, which realize micro electrical discharge deposition, are prejudged according to the discharge phenomena in air and EDM basic theory. Afterwards, a lot of experiments were carried on an ordinary sinking-EDM machine tool. The results of experiments show that wire tool electrode materials, brass, can be deposited on steel workpiece surface. The diameter of micro fabricated cylinders is 100–240 microns, and the height is 1000–7350 microns. On some special machining parameters, a micro spiral structure can be deposited also, which is 100 micron in thread diameter and more than ten cycles. Excepting lots of experiments, the structure and properties of deposited substance were analyzed by SEM, spectroscopy analysis and micro hardness meter and so on. The results of analyzing the deposited cylinders show that the structure is multi-layer, which is beneficial for the further study of 3D scanning machining. The hardness is a little higher than the original metal. In this depositing process, element Zn of tool electrode is almost oxidized to ZnO. Element Cu is not oxidized, existing as solid Cu. Because the reactivity of Cu is weaker than that of Zn.

scholarly journals The potentiality of sinking EDM for micro-impressions on Ti-6Al-4V: keeping the geometrical errors (axial and radial) and other machining measures (tool erosion and work roughness) at minimum

2019 ◽  
Vol 9 (1) ◽  
Author(s):  
Naveed Ahmed ◽  
Saqib Anwar ◽  
Kashif Ishfaq ◽  
Madiha Rafaqat ◽  
Mustafa Saleh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrode Materials ◽  
Dimensional Accuracy ◽  
Negative Polarity ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Dimensional Error ◽  
Industrial Sectors ◽  
Response Measures ◽  
Length Reduction

AbstractTi-6Al-4V is a material of high interest in various industrial sectors including biomedical, automotive and aerospace. Conventional means of machining encounter different types of difficulties. Electric discharge machining (EDM) is not a contest of hardness. Circular impressions of micro-depth are produced in Ti-6Al-4V using four different electrode materials including aluminum, brass, graphite and copper, each assigned positive and negative polarity. In order to get precise control over the geometry of micro-impressions dimensional accuracy and tool wear must be controlled. Thus, EDM performance has been evaluated in terms of axial dimensional error (D.E_Axi), radial dimensional error (D.E_Rad), tool length reduction (TLR), and surface roughness (SR). Since the EDM process is stochastic in nature therefore in addition to tool polarity only two factors are considered as variables, i.e. discharge current and pulse-time-ratio (ration of on-time to off-time). The behaviors of each of the four electrode materials are compared together under each of the two polarities and two variables for each of the four response characteristics. The search is carried out to select the most appropriate tool electrode polarity (common for all responses) and a single common electrode capable of minimizing all the four response measures simultaneously. Moreover, microstructures of the machined impressions are discussed. Without any compromise in the minimum values of response measures, no single polarity and a single electrode are found common. However, with a slight compromise over the machining measures negative tool polarity and copper electrode served the purpose of set objectives (minimum of D.E, TLR, and SR). The expanse of compromise is found to be ≤ 50 µm in axial and radial dimensional errors, 0.8 µm in surface roughness and no compromise in tool length reduction if the copper electrode is assigned with negative polarity.

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