Development of Advanced Alloying Process Using Micro-EDM Deposition Process

Volume 1 ◽  
2004 ◽  
Author(s):  
Ricardo Itiro Ori ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Takashi Nakamura ◽  
Shun-Ichiro Tanaka
Keyword(s):  
Chemical Composition ◽  
Electrical Discharge Machining ◽  
Deposition Process ◽  
Metal Electrode ◽  
Medium Carbon Steel ◽  
Tool Electrode ◽  
Cross Sectional ◽  
Main Metal ◽  
3 Dimensional ◽  
Micro Electrical Discharge Machining

The development of an advanced alloying process using Micro-Electrical Discharge Machining Deposition is described in the present paper. The new process uses a micro-sized bimetal tool electrode, which is composed of two halves; each part made of a different metal. The alloying process of the two metals occurs during the deposition process previously proposed by the authors, which can create 3-dimensional micro-sized objects. The quality of alloyed metal was verified using X-ray analysis. In the present experiment the two metals used are YNi-1 (nickel alloy used in TIG welding) and S45C (medium carbon steel). EPMA results of the obtained deposit show that the nickel and iron distribution in the deposit is uniform when the tool electrode spins during the deposition process. Also, it was found that the chemical composition of the main metal in the deposited object is proportional to the cross sectional area in the bi-metal electrode section. Therefore, not only the deposition process takes place but also the chemical composition of the deposit can be simultaneously controlled using this process.

Micro-EDM Deposition Alloying Process

2004 ◽  
Author(s):  
Ricardo I. Ori ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Takashi Nakamura ◽  
Shun-ichiro Tanaka
Keyword(s):  
Electrical Discharge ◽  
Metal Electrode ◽  
Medium Carbon Steel ◽  
Tool Electrode ◽  
Micro Edm ◽  
Cross Sectional ◽  
Medium Carbon ◽  
X Ray ◽  
Work Surface ◽  
Eds Analysis

A new deposition alloying process using Micro-EDM was developed. Using the energy released by the electrical discharge, material from the tool electrode is melted and deposited over the work surface. When a rotating bi-metal tool electrode is fed towards the work surface, the alloying between its elements occurs during process. The obtained results of the alloying between nickel and iron are presented in the present paper, when the components of the bi-metal tool electrode are made of YNi-1 (nickel alloy used in TIG welding — JIS standard) and medium carbon steel (S45C — JIS standard). X-ray and EDS analysis have shown that the chemical composition of the obtained deposit can be controlled and is proportional to the cross sectional area of each element present in the bi-metal electrode. With this process, a material with the same composition of Invar was successfully deposited.

scholarly journals An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

2017 ◽  
Vol 64 (2) ◽  
pp. 149-163 ◽  
Author(s):  
Govindan Puthumana
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Micro Edm ◽  
Modeling And Analysis ◽  
Micro Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Main Effect

AbstractTo achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a regression relationship between tool wear ratio and the process inputs has been developed.

Fabrication of Functional Gradient Materials Electrode and its Application in Micro-EDM

2017 ◽  
Vol 868 ◽  
pp. 151-157
Author(s):  
Xiao Peng Li ◽  
Yuan Gang Wang ◽  
Fu Ling Zhao ◽  
Meng Hua Wu
Keyword(s):  
Electrical Discharge Machining ◽  
Gradient Material ◽  
Homogeneous Material ◽  
Tool Electrode ◽  
Micro Edm ◽  
Gradient Materials ◽  
Functional Gradient ◽  
Micro Electrical Discharge Machining ◽  
Functional Gradient Material ◽  
Edm Process

The concept and the primary preparation method of functional gradient materials are described in this paper. Functional gradient material is prepared as a tool electrode by electrochemical method and its performance is further tested in the micro electrical discharge machining (micro-EDM) experiments. Compared with the homogeneous material electrode, the functional gradient material electrode can effectively inhibit the wearing of the tool electrode and improve the distribution trend of current density during the micro-EDM process. The results disclose the prospects for functional gradient material to be used as tool electrode in the micro-EDM process.

Scanning Micro-Electrochemical Machining Process for V-Shaped Grooves

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Hao Zhong ◽  
Hao Tong ◽  
Zhiqiang Wang ◽  
Yong Li ◽  
Yubin Pu
Keyword(s):  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Microfluidic Chips ◽  
Long Distance ◽  
High Surface Quality ◽  
Micro Electrical Discharge Machining ◽  
The Given

Abstract Microstructures determine flow properties of microfluidic chip. Micromold forming is an effective method to realize mass manufacturing of microfluidic chips. This requires to machine some kind of special microstructure of high surface quality on a metal/alloy workpiece. Micro V-shaped grooves are the typical microstructures of the chip micromolds used for controlling microfluid or weld packaging. In this research, a scanning micro-electrochemical machining (ECM) process of V-shaped grooves is proposed using a tool electrode fabricated by micro–electrical discharge machining (EDM) on-machine. Theoretical and experimental research was conducted for achieving the V-shaped grooves with a given angle on die steel. A long-distance V-shaped groove with the given angle of 67 deg and the depth of 125 μm was successfully machined.

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.

Study on Micro Reversible Electrical Discharge Machining Method for the Fabrication of Micro Structures

2009 ◽  
Vol 626-627 ◽  
pp. 279-284 ◽  
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Yu Kui Wang ◽  
Ying Huai Dong ◽  
H. Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Deposition Process ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Steel Material ◽  
Machining System ◽  
Micro Structures ◽  
Edm Process ◽  
Better Than

A reversible machining method using micro electrical discharge machining (EDM) was developed. This new method can achieve depositing or selective removing of metal material for the fabrication of micro structures. It is easy to transform the machining process from deposition to removal in one EDM machining system. In micro EDM deposition process, brass, tungsten and steel material can be deposited successfully. The deposited material has compact fine texture and combines close to workpiece. Then, micro complex structures by series deposition strategy and sub-deposition strategy were deposited. In the selective removal process, the machining effects of different working mediums were researched. Results show that the machining effect in liquid medium is better than that of in air. Finally, using the micro reversible EDM process, a micro square column with 0.070mm in side length, 0.750mm in height and a micro cylinder with 0.140mm in diameter, 1.180mm in height were fabricated.

Material Removal and Fracture Detection in Micro-EDM Processes

2011 ◽  
Vol 462-463 ◽  
pp. 1092-1096 ◽  
Author(s):  
Muslim Mahardika ◽  
Gunawan Setia Prihandana ◽  
Takashi Endo ◽  
Suyitno ◽  
B. Arifvianto ◽  
...  
Keyword(s):  
Pulse Energy ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Micro Machining ◽  
Fracture Detection ◽  
Charge Voltage ◽  
Discharge Pulse ◽  
Micro Electrical Discharge Machining

The important thing in micro-machining is its accuracy. The Micro-Electrical Discharge Machining (micro-EDM) is a promising method in micro-machining, because (1) the process is independent on the hardness of the workpiece but only depends on its thermal conductivity and melting point and (2) it can be used to machine materials with highly complex geometrical shapes using a simple-shaped tool electrode. However, the process in micro-EDM is not totally well-known, especially related to the formation of discharge pulse energy and the fracture phenomena. In the micro-EDM processes, the formation of discharge pulse energy is a complex phenomenon, since it is related to many parameters such as discharge gap, charge voltage, capacitance, and tool electrode wear. In this paper, the Acoustic Emission (AE) sensor is used to detect the changes of discharge pulse energy during machining of brass using micro-EDM. The results shows that the AE signals can detect and explain the fracture phenomena during the micro-EDM processes.

scholarly journals Study of Electrical Discharge Machining Parameters on Stainless Steel Using Copper Tool Electrode and Its Effect on the Structure and Electrochemical Properties

2021 ◽  
Vol 68 (2) ◽  
pp. 279-288
Author(s):  
Mozhgan Karimi ◽  
Sayyed Ahmad Nabavi-Amri ◽  
Ahmad Soleymanpour
Keyword(s):  
Stainless Steel ◽  
Chemical Composition ◽  
Discharge Current ◽  
Electrical Discharge Machining ◽  
Electrochemical Impedance ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Micro Cracks ◽  
Pulse On Time ◽  
Pulse Off Time

In this work, the effect of the presence and the diffusion of the Copper from the tool electrode onto the EDMed stainless steel (SS) surface have been investigated by electrochemical impedance spectroscopy (EIS), X-ray diffraction (XRD), Quantometer analysis, and Optical microscopic observations. The Taguchi method was used to study the effects of Pulseon time (ton), Pulse-off time (toff), discharge current (I), and overall machining time (τ) on chemical composition, microstructures, micro-cracks, and electrochemical corrosion of EDMed stainless steel workpieces. The results show that the variation of machining parameters changes the chemical composition of the workpieces. By increasing the discharge current and decreasing the Pulse-on time, the copper and the carbon diffuse onto the surface of the workpiece. Consequently, the chemical composition of the workpiece surface changes, leading to an increment of the corrosion resistance. The XRD analysis shows the formation of Fe2C, Cr3C2, and CuNi. In addition, at higher values of discharge current and ton/toff ratio, the micro-cracks propagate on the surface of the workpiece.

Experimental Research of Micro Reversible Electrical Discharge Machining

2009 ◽  
Vol 69-70 ◽  
pp. 177-181
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Ying Huai Dong ◽  
Hui Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Metallurgical Bonding ◽  
Machining System ◽  
Micro Structures ◽  
Edm Process

Based on the principle of micro electrical discharge machining (EDM), a reversible machining method is proposed, which can achieve depositing or removing selectively metal material for the fabrication of micro structures. It is easy to transform the machining process from deposition to removal in one machining system. The characteristics of the deposited material show that the components of deposited material are almost the same as those of the tool electrode, and the metallurgical bonding has formed on the interface between the deposited material and the base. Moreover, the deposited material has well machinability in different micro EDM selective removal process, including micro EDM die-sinking and micro EDM milling. As a result, a micro square column with 0.1mm in side length, 0.88mm in height and a micro cylinder with 0.14mm in diameter, 1.18mm in height were fabricated by using the micro reversible EDM process.

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