Experimental Characterization of Vibration-Assisted Reverse Micro Electrical Discharge Machining (EDM) for Surface Texturing

2012 ◽  
Author(s):  
Sachin Mastud ◽  
Mayank Garg ◽  
Ramesh Singh ◽  
Johnson Samuel ◽  
Suhas Joshi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hierarchical Structures ◽  
Textured Surface ◽  
Fish Scale ◽  
Textured Surfaces ◽  
Process Stability ◽  
Lotus Leaf ◽  
Micro Electrical Discharge Machining ◽  
Lotus Leaves

There are several examples in nature where the biological surfaces exhibit unique functional response, such as velcro, fish scale and lotus leaves. The texture on lotus leaf exhibits super-hydrophobicity and self cleaning properties. Lotus leaf has hemispherical protrusions of 20–30 μm in diameters which are randomly distributed over the surface. This work is focused on creating similar textured surfaces on Ti6Al4V rods via a vibration assisted reverse micro Electrical Discharge Machining (R-MEDM) process. Textured surfaces containing micropillars of 40–50 μm in diameter spaced at 35 μm have been created during the process. These textured surfaces are expected to exhibit hydrophobicity and hemocompatibility. To experimentally characterize the process, a full factorial design of experiments has been conducted to analyze the effects of voltage, capacitance, amplitude and frequency of the anode (plate electrode) vibrations on the erosion rate and process stability. The process stability is expressed in terms of the percentages of the normal, open circuit and the short circuit durations in the voltage-current (VI) signature obtained during the process. It has been observed that the normal discharge durations increase with an increase in the amplitude and the frequency of the vibrations. Fabricated texture exhibits hydrophobicity and the measured contact angles in a sessile drop test with water varied between 110 and 115°. Also, the textured surface was subjected to hemotoxicity tests which yielded positive results. Based on these results, it can be seen that the machined textured surface are hydrophobic and biocompatible in nature which could potentially find applications in cardiovascular biomedical implants. In addition, this process has been used to create hierarchical structures comprising of primary and a secondary structure over it to mimic the hierarchical structures found on lotus leaves.

Recent Patents on Micro-EDM Milling

2020 ◽  
Vol 13 (3) ◽  
pp. 219-229
Author(s):  
Baocheng Xie ◽  
Jianguo Liu ◽  
Yongqiu Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Processing Method ◽  
Electrode Wear ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Processing Methods ◽  
Machining Quality ◽  
Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Micro electrical discharge machining in nitrogen plasma jet

2018 ◽  
Vol 51 ◽  
pp. 198-207 ◽  
Author(s):  
Rimao Zou ◽  
Zuyuan Yu ◽  
Chengyang Yan ◽  
Jianzhong Li ◽  
Xin Liu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Plasma Jet ◽  
Nitrogen Plasma ◽  
Micro Electrical Discharge Machining

A Magnetic Drive Actuator for Micro Electrical Discharge Machining

2012 ◽  
Vol 591-593 ◽  
pp. 303-306
Author(s):  
Xiao You Zhang ◽  
Akio Kifuji ◽  
Dong Jue He
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Degrees Of Freedom ◽  
Electrical Discharge Machining ◽  
Magnetic Coupling ◽  
Magnetic Bearings ◽  
Coupling Mechanism ◽  
Micro Electrical Discharge Machining ◽  
Long Stroke ◽  
Magnetic Drive

Electrical discharge machining has the capability of machining all conductive materials regardless of hardness, and has the ability to deal with complex shapes. However, the speed and accuracy of conventional EDM are limited by probability and efficiency of the electrical discharges. This paper describes a three degrees of freedom (3-DOF) controlled, wide-bandwidth, high-precision, long-stroke magnetic drive actuator. The actuator can be attached to conventional electrical discharge machines to realize a high-speed and high-accuracy EDM. The actuator primarily consists of thrust and radial magnetic bearings, thrust and radial air bearings and a magnetic coupling mechanism. By using the thrust and radial magnetic bearings, the translational motions of the spindle can be controlled. The magnetic drive actuator possesses a positioning resolution of the order of micrometer, a bandwidth greater than 100Hz and a positioning stroke of 2mm.

scholarly journals Implementation of a micro-electrical discharge machining system to fabricate TiO2 nanocolloid

Mechatronics ◽  
2021 ◽  
Vol 79 ◽  
pp. 102649
Author(s):  
Kuo-Hsiung Tseng ◽  
Kuo-Hui Chen ◽  
Chaur-Yang Chang ◽  
Yagus Cahyadi ◽  
Meng-Yun Chung
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Micro Electrical Discharge Machining ◽  
Machining System

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

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