Modeling of a Single Resistance Capacitance Pulse Discharge in Micro-Electro Discharge Machining

2005 ◽  
Vol 127 (4) ◽  
pp. 759-767 ◽  
Author(s):  
Sandeep Dhanik ◽  
Suhas S. Joshi
Keyword(s):  
Material Removal ◽  
Pulse Generator ◽  
Pulse Discharge ◽  
Plasma Temperature ◽  
Micro Edm ◽  
Variable Source ◽  
Electro Discharge Machining ◽  
Single Discharge ◽  
Edm Process ◽  
Lower Discharge

Micro-EDM (electro discharge machining) is a derived form of EDM process especially evolved for micro-machining. The use of resistance capacitance pulse generator, an advanced controller for machining in smaller interelectrode gaps and with lower discharge energies than in EDM, makes the material removal characteristics of a single discharge in micro-EDM different from that of the EDM. A comprehensive model predicting the material removal in a single discharge in micro-EDM is conceptualized. The model incorporates various phenomena in the prebreakdown period. It considers plasma as a time-variable source of energy to the cathode and anode to evaluate material removal at the electrodes. The plasma temperature and radius of the crater at the cathode (workpiece) predicted using the model were found to agree well with the experimental data in the literature.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

Enhancing the Surface Quality by Iso Pulse Generator in EDM Process

2012 ◽  
Vol 622-623 ◽  
pp. 380-384 ◽  
Author(s):  
T. Muthuramalingam ◽  
B. Mohan
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Discharge Energy ◽  
Crater Volume ◽  
Machining Characteristics ◽  
Edm Process

In automobile and aeronautical industries, complex moulds and dies is produced by Electrical Discharge Machining process. The surface finish is determined by the crater volume in EDM process. The amount of crater volume is influenced by the amount and distribution of discharge energy. The discharge energy is directly proportional to the average discharge current. This amount of current is determined by the duration of discharging effect. This study deals about evaluating the performance of iso current pulse generator on machining characteristics in EDM. Due to its ability of reducing stochastic nature in EDM process, iso pulse generator could produce better surface finish than conventional transistor pulse train generator with higher material removal rate.

scholarly journals A study of micro-electro discharge machining electrode wear

2007 ◽  
Vol 221 (5) ◽  
pp. 605-612 ◽  
Author(s):  
D T Pham ◽  
A Ivanov ◽  
S Bigot ◽  
K Popov ◽  
S Dimov
Keyword(s):  
Electrode Wear ◽  
Micro Edm ◽  
Volumetric Wear ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Electrode Shape ◽  
Compensation Methods ◽  
Geometrical Information ◽  
Edm Drilling ◽  
Edm Process

This paper studies the influence of factors contributing to electrode wear during the micro-electro discharge machining (EDM) process. The paper proposes a method for calculating the volumetric wear ratio based only on geometrical information obtained from the process. The objective of the work is to investigate the suitability of micro-EDM electrode wear compensation methods. Electrode shape deformation and random variations in the volumetric wear are studied as two main factors affecting the applicability of wear compensation methods as well as indicating the accuracy achievable with micro-EDM. EDM drilling and EDM milling are regarded as separate processes as they require different approaches in investigating and implementing the results of the study.

Electro-Discharge Machining of Aluminum Alloy with Nickel Powder-Mixed Dielectric

2018 ◽  
Vol 3 (2) ◽  
pp. 49
Author(s):  
Srinivasa Rao P ◽  
Eshwara Prasad K
Keyword(s):  
Material Removal ◽  
Nickel Powder ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Nickel Concentration ◽  
Powder Concentration ◽  
Electro Discharge Machining ◽  
Nickel Powders ◽  
Electrode Discharge ◽  
Edm Process

Powder-mixed dielectric fluid is one of the innovations of electrode-discharge machining (EDM) which seeks to improve the process outputs by addition of Nickel powders to the dielectric during machining. In the present study, the influence of Nickel powder in kerosene dielectric fluid on EDM process outputs was investigated.  Experiments were conducted with the outputs as material removal rate (MRR) and surface roughness(Ra). During the EDM, the discharge current was varied between 3 and 15 A, while powder concentration ranges between 2 and 10 g/l.  Results indicate that the highest MRR of  39.888 mm3 /min was obtained with Nickel powder concentration of 6 g/l at the current of  9A, where as the lowest SR of  3.397 μm was obtained with Nickel concentration of 3 g/l at the current of 3A.

Monitoring System for the Micro EDM Process

2012 ◽  
Author(s):  
Jayakumar Narasimhan ◽  
Kamlakar P. Rajurkar
Keyword(s):  
Electrical Discharge ◽  
Lead Time ◽  
Material Removal ◽  
Online Monitoring ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Current Signal ◽  
The Cost ◽  
Edm Process

Now-a-days, many sophisticated systems are available to monitor the process in real time that drastically reduce the cost and lead time to manufacture a part because it takes away the offline sampling. For Electrical Discharge Machining (EDM), current signal monitors are very useful to predict the material removal rate and determine the arcing that can damage the surface. This paper discusses the design and development of an online monitoring for micro-EDM using correlation developed via experimentation. Surface roughness is predicted based on online monitoring.

scholarly journals Material removal mechanism in low-energy micro-EDM process

CIRP Annals ◽  
2015 ◽  
Vol 64 (1) ◽  
pp. 225-228 ◽  
Author(s):  
Jun Qian ◽  
Fei Yang ◽  
Jun Wang ◽  
Bert Lauwers ◽  
Dominiek Reynaerts
Keyword(s):  
Material Removal ◽  
Low Energy ◽  
Micro Edm ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Edm Process

Acoustic Emission Signals in the Micro-EDM of PCD

2008 ◽  
Vol 33-37 ◽  
pp. 1181-1186 ◽  
Author(s):  
M. Mahardika ◽  
Kimiyuki Mitsui ◽  
Zahari Taha
Keyword(s):  
Acoustic Emission ◽  
Elastic Wave ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Single Discharge ◽  
Ae Signals

The mechanism of fracture in micro-electrical discharge machining (-EDM) processes is related to the discharge pulses energy. This paper investigates the correlation of fractures and discharge pulses energy in the -EDM of polycrystalline diamond (PCD) to the acoustic emission (AE) signals. The evaluation of fracture mechanism was done by measuring the generation and propagation of elastic wave in single discharge pulse by using AE sensor. The results show a strong correlation between fractures and discharge pulses energy to the AE signals and mechanism of material removal in the -EDM processes.

Analysis and Simulation of Micro Electro Discharge Machining Process

2007 ◽  
Author(s):  
Dedong Gao ◽  
Ling Tian
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Machining Process ◽  
Micro Edm ◽  
Analysis Model ◽  
Element Analysis ◽  
Electro Discharge Machining ◽  
Numeric Simulation

Based on the basic thermal conductivity theory and the fact of micro electro discharge machining (micro-EDM), a finite element analysis model of micro-EDM is proposed. Through finite element analysis software ANSYS, the temperature field distribution of the single pulse discharge is simulated under the different heat source condition. It can be seen from the results that the shape of discharge crater is similar to that of molten zone of the temperature distribution. The surface roughness and material removed rate of single pulse discharge are calculated and analyzed by the numeric simulation results.

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