Micro Electro Discharge Milling of Freeform Micro-Features With High Aspect Ratio

2011 ◽  
Author(s):  
F. Modica ◽  
V. Marrocco ◽  
G. Trotta ◽  
I. Fassi
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Fill Factor ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Surface ◽  
Adjustment Factor ◽  
Machining Performance ◽  
Technological Parameters ◽  
Micro Features

Micro Electrical Discharge Machining (μEDM) technology is widely used to process conductive materials, regardless to their hardness and strength, and realize micro-sized feature components for industrial application. μEDM proves to be a very competitive fabrication technology since micro-sized features within 1 μm of accuracy and with high surface quality (<0.1 μm Ra) can be attained. When High Aspect Ratio (HAR) micro-features are machined via μEDM milling, the main problem is to identify the technological parameters and settings mainly affecting the process performance. In the present study the influence of the adjustment factor and flushing conditions are investigated and discussed for the machining of HAR cavities with different Fill Factor (FF). Material Removal Rate (MRR) and Tool Wear Ratio (TWR) are evaluated when deep cavities having variable square sections are machined on Ni-Cr-Mo steel workpiece. All tests are performed using a state of the art micro-EDM milling machine, with a Tungsten Carbide electrode tool and a dielectric oil for flushing. The experimental results presented here highlight different trends in the machining performance in dependence of AR and FF. In particular, MRR exhibits a decreasing trend where the curve slopes are strictly related to the FF and the initial adjustment factor. On the contrary, TWR, for higher FF, displays two distinct trends characterized by opposite slopes in each curve. Finally a nozzle for micro-injection with varying Aspect Ratio and Fill Factor is machined and presented as demonstrator.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

scholarly journals An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6074
Author(s):  
Tingting Ni ◽  
Qingyu Liu ◽  
Zhiheng Chen ◽  
Dongsheng Jiang ◽  
Shufeng Sun
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Deionized Water ◽  
Micro Edm ◽  
Nano Particle ◽  
Machining Performance ◽  
Machined Surface ◽  
Micro Electrical Discharge Machining ◽  
Lower Tool

Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

scholarly journals Atomic Layer Deposition of GdCoO3 and Gd0.9Ca0.1CoO3

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 24
Author(s):  
Marion Duparc ◽  
Henrik Hovde Sønsteby ◽  
Ola Nilsen ◽  
Anja Olafsen Sjåstad ◽  
Helmer Fjellvåg
Keyword(s):  
Thin Films ◽  
Aspect Ratio ◽  
Atomic Layer Deposition ◽  
High Aspect Ratio ◽  
High Surface ◽  
High Surface Area ◽  
Atomic Layer ◽  
Oxidation Catalysis ◽  
Post Annealing ◽  
Layer Deposition

Thin films of the catalytically interesting ternary and quaternary perovskites GdCoO3 and Gd0.9Ca0.1CoO3 are fabricated by atomic layer deposition using metal β-diketonates and ozone as precursors. The resulting thin films are amorphous as deposited and become single-oriented crystalline on LaAlO3(100) and YAlO3(100/010) after post-annealing at 650 °C in air. The crystal orientations of the films are tunable by choice and the orientation of the substrate, mitigated through the interface via solid face epitaxy upon annealing. The films exhibit no sign of Co2+. Additionally, high-aspect-ratio Si(100) substrates were used to document the suitability of the developed process for the preparation of coatings on more complex, high-surface-area structures. We believe that coatings of GdCoO3 and Gd1−xCaxCoO3 may find applications within oxidation catalysis.

Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM

2013 ◽  
Vol 675 ◽  
pp. 365-369 ◽  
Author(s):  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Hai Ping Tsui ◽  
Yuan Feng Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Dielectric Fluids ◽  
Edm Process

The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

Effects of Electrical Discharge Energy on Machining Performance of Sintered NdFeB Magnet

2009 ◽  
Vol 620-622 ◽  
pp. 711-714 ◽  
Author(s):  
Li Li ◽  
Guang Ming Yuan ◽  
Zong Wei Niu ◽  
Rong Guo Hou
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Discharge Energy ◽  
Machining Performance ◽  
Ndfeb Magnet ◽  
Machined Surface ◽  
Micro Cracks ◽  
Ndfeb Permanent Magnet

Sintered NdFeB permanent magnet is widely used in many areas because of its excellent magnet property. In this study, the machining parameters of electrical discharge machining (EDM) are varied to study the effects of electrical discharge energy on material removal rate and surface roughness of NdFeB magnet. Moreover, the micro-cracks on the machined surface induced by EDM are also examined. The experimental results reveal that the MRR increases with the electrical discharge energy. The number of surface cracks on the machined surface increases with the enhancement of discharge energy Thus, using EDM process to machine sintered NdFeB magnet depends on setting the machining parameters to prevent surface crack.

Electrical Discharge Machining of SiC and Gr Reinforced 6061-T6 Aluminum Alloy Hybrid Composite Fabricated by Friction Stir Processing

2013 ◽  
Author(s):  
Murahari Kolli ◽  
Devaraj Aruri ◽  
Kumar Adepu
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Machining Performance ◽  
Friction Stir

Aluminum based hybrid composites are advanced materials having the properties of high hardness, superior wear resistance, strength, high elevated temperature and low thermal expansion coefficient. These hybrid composites are widely used in industries like automobile and aerospace. In this present paper 6061-T6 Aluminum alloy reinforced with SiC and Gr particles, hybrid composites are fabricated by using Friction stir processing (FSP) technique. It prevents the further development of hybrid composites for machining by nonconventional methods like water jet and laser cutting process. Electrical discharge machining (EDM) is used for machining the complex shapes of the material. This paper presents an overview of EDM studies conducted on the Al-SiC/Gr hybrid composites using a copper electrode in EDM. The EDM experiment machining parameters such as the dielectric fluid, peak current, pulse on, pulse off times are changed to explore their effects on machining performance, material removal rate (MRR), Tool wear rate (TWR), and surface roughness (SR). It is observed that the MRR and SR of the Al-SiC/Gr hybrid composites increase with an increase in the current.

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