scholarly journals Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

2015 ◽  
Author(s):  
Arvind Pattabhiraman ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Material Removal ◽  
Sustainable Manufacturing ◽  
Dielectric Medium ◽  
Discharge Zone ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electrode Gap ◽  
Dry Edm ◽  
Debris Particles ◽  
Edm Electrodes

A novel method of using atomized dielectric spray in EDM to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the inter-electrode gap and acts as a single phase dielectric medium between the electrodes and also effectively removes the debris particles from the discharge zone. EDM experiments are performed using three different dielectric supply methods, viz., conventional wet-EDM (electrodes submerged in dielectric medium), dry-EDM and spray-EDM in order to compare the processes based on material removal, tool electrode wear and flushing of debris from the inter-electrode gap across a range of discharge energies. It is observed that spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study. The tool electrode wear using atomized dielectric is significantly better than dry-EDM and comparable to that observed in conventional wet-EDM. The percentage of debris particles deposited within a distance of 100 μm from the center of EDM crater is also significantly reduced using the atomized dielectric spray EDM technique.

Atomized Dielectric Spray-Based Electric Discharge Machining for Sustainable Manufacturing

2015 ◽  
Vol 3 (4) ◽  
Author(s):  
Arvind Pattabhiraman ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Dielectric Medium ◽  
Discharge Zone ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Dry Edm ◽  
Debris Particles ◽  
Interelectrode Gap

A novel method of using atomized dielectric spray in micro-electric discharge machining (EDM) (spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the interelectrode gap and acts as a single phase dielectric medium between the electrodes and also effectively removes the debris particles from the discharge zone. Single-discharge micro-EDM experiments are performed using three different dielectric supply methods, viz., conventional wet-EDM (electrodes submerged in dielectric medium), dry-EDM, and spray-EDM in order to compare the processes based on material removal, tool electrode wear, and flushing of debris from the interelectrode gap across a range of discharge energies. It is observed that spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study. The tool electrode wear using atomized dielectric is significantly better than dry-EDM and comparable to that observed in wet-EDM. The percentage of debris particles deposited within a distance of 100 μm from the center of EDM crater is also significantly reduced using the spray-EDM technique.

High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

THEORETICAL DEFINITION FOR QUALITY PARAMETERS OF SURFACE LAYER IN PARTS, TOOL-ELECTRODE WEAR AND PROCESS PRODUCTIVITY AT ELECTROEROSION MACHINING

2016 ◽  
Vol 2016 (1) ◽  
pp. 67-73 ◽  
Author(s):  
Сергей Съянов ◽  
Sergey Syanov
Keyword(s):  
Surface Layer ◽  
Material Removal ◽  
Solid Material ◽  
Quality Parameters ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Factors Affecting ◽  
Electric Erosion ◽  
Machining Properties ◽  
Process Productivity

An electric erosion process serves as a basis for electroerosion machining (EEM) as a result of which occurs a material removal from the surface of a product. The destruction of electrode surface takes place at the expense of melting and partial evaporation of material. As a result of this the cavities called holes remain on a surface and also changes arise on the surface layer of a billet. A microrelief of a surface is formed with considerable quantity of mutually covered holes having different geometrics the knowledge of which allowed determining height and pitch parameters of roughness. Upon a corrugation formation at electroerosion machining has an influence a lot of factors which may be or may be not depending on a machining procedure and on whether machining is to be carried out on solid material or a surface prepared earlier should be machined. To the basic factors affecting the surface corrugation at EEM should be referred parameters conditioned on the influence of a billet initial corrugation, tool initial corrugation, influence of fluctuations in technological modes of machining. Having defined these parameters it should be possible to compute a corrugation at EEM. To analyze microhardness and residual stresses at EEM, first, it should be necessary to know a temper-ature field distribution in the surface layer of a product that will allow defining quality parameters mentioned above. To determine volumetric wear of a tool-electrode and EEM productivity it should be necessary to know the following: physical stress-strain properties of work material and material of a tool-electrode; modes of electro-erosion machining; properties of dielectric liquid.

Research of the Basic Physical Regularities of Material Removal in Electrical Discharge Machining of Tool Steel

2017 ◽  
Vol 756 ◽  
pp. 96-106
Author(s):  
Ľuboslav Straka ◽  
Slavomíra Hašová
Keyword(s):  
Tool Steel ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Main Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Workpiece Material ◽  
The Individual ◽  
Selection Of

The paper describes the basic physical regularities of material removal in Electrical discharge machining (EDM) of tool steel. One of the parameters, that material removal regularities quite accurately identifies, is the tool wear rate (TWR). This parameter, however, describes only the regularities concerning the tool electrode wear. More complex parameter for assessing regularities of material removal in EDM is thus electrode wear ratio (EWR). This parameter, except the size of the wear of the tool electrode, also describes the size of the workpiece material removal. Research on material removal was carried out on samples made out of tool steel EN X32CrMoV12-28 using Cu-ETP electrode EN CW004A. Aim of this paper was also based on the selection of main process parameters that significantly influence the material removal in EDM to define the individual specifics with regard to minimizing EWR.

Study of Tool Electrode Wear in EDM Process

2015 ◽  
Vol 669 ◽  
pp. 302-310 ◽  
Author(s):  
Ľuboslav Straka ◽  
Slavomíra Hašová
Keyword(s):  
Material Removal ◽  
Electrical Discharge Machining ◽  
Electrical Energy ◽  
Metal Particles ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electrical Discharges ◽  
Workpiece Material ◽  
Edm Process

Technology of Electrical Discharge Machining (EDM) uses thermal energy in material removal, in which is the electrical energy transformed, generated between the electrodes (tool and workpiece). The material removal occurs through the rapid periodic repetitive electrical discharges in the presence of dielectric fluid. By the action of electrical discharges occurs to decline not only particles of a metal workpiece material, but also to decline in a certain proportion of metal particles in tool electrode. The paper deals with the diagnosis the size of the electrode wear of tools made from copper and graphite used in EDM machining.

Experimental Study on Submersed Gas-Jetting EDM

2008 ◽  
Author(s):  
X. M. Kang ◽  
W. S. Zhao ◽  
C. J. Tang ◽  
L. S. Ding
Keyword(s):  
Experimental Study ◽  
High Pressure ◽  
Pulse Duration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dielectric Medium ◽  
New Method ◽  
Electrode Wear ◽  
Tubular Electrode

A new method called submersed gas-jetting EDM was proposed, in which the high-pressure gas working as the dielectric medium, is blown throughout the inner hole of a tubular electrode, and machining liquid around the gas plays significant roles of helping cooling and debris evacuation but doesn’t involve in the discharge directly. Experiments were conducted to investigate the influence of polarity, pulse duration, peak current, gas pressure and different gas/machining liquid combination. The comparison of submersed gas-jetting EDM and dry EDM indicated that this new method revealed higher material removal rate (MRR), better surface quality and equivalently minute electrode wear.

scholarly journals Comparative Analysis of Dry-EDM and Conventional EDM in machining of Hastelloy

2021 ◽  
Vol 12 (3) ◽  
pp. 3538-3543
Author(s):  
Apurva A Kulkarni Et.al
Keyword(s):  
High Velocity ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Dielectric Medium ◽  
Work Piece ◽  
Tool Electrode ◽  
Dry Edm ◽  
Discharge Gap ◽  
Edm Process

Dry EDM may be a modification of the traditional electrical discharge machining (EDM) process during which the liquid dielectric is replaced by a gaseous medium. High velocity gas is supplied through it into the discharge gap. The flow of high velocity gas into the gap facilitates removal of debris and prevents excessive heating of the tool and work piece at the discharge spots. it's now known that aside from being an environment–friendly process, other advantages of the dry EDM process are low tool wear, lower discharge gap, lower residual stresses, smaller white layer and smaller heat affected zone.[1] Keeping literature review into consideration, during this research, an effort has been made by selecting compressed gas as a dielectric medium, with Hastelloy as a work piece material and copper as a tool electrode. Conventional experiments were also performed. Experiments are performed using Taguchi DoE orthogonal array to watch and analysis the consequences of various process parameters to optimize the response variables like material removal rate (MRR) and gear wear rate (TWR).

Experimental Research on Technology of Ultrasonic Vibration Aided Electrical Discharge Machining (UEDM) in Gas

2006 ◽  
Vol 315-316 ◽  
pp. 81-84 ◽  
Author(s):  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Q.B. Zhang ◽  
Shu Peng Su
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Environment Pollution ◽  
Dielectric Fluids

Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is an electrical discharge machining (EDM) technology, in which gases such as air and oxygen are used as dielectrics and ultrasonic vibration is applied. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also possesses virtues of wide applications, high machining efficiency and simple tool electrodes and so on. The principle of UEDM in gas is introduced in this paper. Experiments have been carried out to study the effects of machining parameters on material removal rate (MRR), surface roughness of the workpiece and tool electrode wear ratio (TWR), and the experiments results have also been analyzed.

scholarly journals Study on Mechanism for Minute Tool Electrode Wear in Dry EDM.

1999 ◽  
Vol 65 (5) ◽  
pp. 689-693 ◽  
Author(s):  
Masahiro YOSHIDA ◽  
Masanori KUNIEDA
Keyword(s):  
Tool Electrode ◽  
Electrode Wear ◽  
Dry Edm
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