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.

Alloy Inconel 718 by 3D Micro-Electro Discharge Machining

2014 ◽  
Vol 590 ◽  
pp. 239-243 ◽  
Author(s):  
Piyapong Kumkoon ◽  
Chana Raksiri ◽  
Chaiyakorn Jansuwan
Keyword(s):  
Inconel 718 ◽  
Micro Edm ◽  
Optimal Parameters ◽  
Electro Discharge Machining ◽  
Debris Removal ◽  
Micro Drilling ◽  
Voltage Frequency ◽  
Off Time ◽  
Edm Drilling ◽  
Edm Process

This article aims to show the effects of the Micro-EDM process that influences the hole taper by comparing the parameters values during micro-drilling hole on the inconel 718 material. The condition of Micro-EDM drilling spark on the surface workpiece was 300 μm of depth and 200 μm of diameter tungsten carbide electrode. The experiment was carried out under the cover of hydrocarbon, using fluid dielectric cooling. The experiment parameters included on-time duty factor, off-time, voltage, frequency, and current, respectively. The experiment, it was found that the hole taper an immense effect on the machinability of drilling the workpieces, cause melting and recasting in the spark area, making a decrease in the ability of debris removal. Moreover, the experiment result, the tapered workpiece showed a minimized is 16.87 s, when using parameters at current 32 mA, frequency 150 Hz, and voltage 110 v, respectively. The optimal parameters to affected minimum hole taper is 0.195 degree, when using parameters at current 32 mA, frequency 130 Hz, and voltage 110 v, respectively.

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.

Investigation on the Influence of Machining Fluid on Processing Characteristics in Micro-EDM

2012 ◽  
Vol 479-481 ◽  
pp. 407-413 ◽  
Author(s):  
Sha Li ◽  
Wataru Natsu ◽  
Takeshi Masaki ◽  
Zu Yuan Yu
Keyword(s):  
Feed Rate ◽  
Deionized Water ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Machining Speed ◽  
Small Electrode ◽  
Short Circuits ◽  
Edm Drilling

In this paper the influence of machining liquid on the processing characteristics, such as the tool electrode wear and the tool actual feed were discussed. Micro EDM drilling was carried out using deionized water and oil dielectric as the machining liquid. It was found that using deionized water reduced the tool electrode wear. Also, occurrence of short-circuits during the processing is one of the reasons for causing large electrode wear. In the case of using oil dielectric, processed depth influences the tool electrode wear greatly and causes the change in the actual feed rate. While using deionized water, processed depth also causes the change in the actual feed rate, but nearly had no influence on the tool electrode wear. Meanwhile, when using deionized water, although the small electrode wear and high machining speed can be obtained, electrolytic dissolution may occur. Therefore, the effective method of decreasing the open voltage and increasing the feed rate to prevent the electrolytic dissolution was mentioned and experimentally verified.

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.

scholarly journals Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 989 ◽  
Author(s):  
Manu Goiogana ◽  
Ahmed Elkaseer
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Cylindrical Shape ◽  
Specific Response ◽  
Cylindrical Electrode ◽  
Taper Angle ◽  
Electrode Shape ◽  
Edm Drilling ◽  
Edm Process

This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

An investigation of tube and rod electrode wear in micro EDM drilling

2006 ◽  
Vol 33 (1-2) ◽  
pp. 103-109 ◽  
Author(s):  
D. T. Pham ◽  
A. Ivanov ◽  
S. Bigot ◽  
K. Popov ◽  
S. Dimov
Keyword(s):  
Electrode Wear ◽  
Micro Edm ◽  
Edm Drilling

Indirect Approach to Ultrasonic Superposition in Micro-EDM

2011 ◽  
Author(s):  
Andreas Schubert ◽  
Nicolas Wolf ◽  
Henning Zeidler ◽  
Jo¨rg Schneider
Keyword(s):  
Ultrasonic Vibration ◽  
Large Scale ◽  
Stable Condition ◽  
Resonant Mode ◽  
Discharge Zone ◽  
Micro Edm ◽  
Serial Production ◽  
Electro Discharge Machining ◽  
First Results ◽  
Edm Process

Micro Electro Discharge Machining is a well known process for machining microstructures with highest precision in hard and brittle or tough materials. The deeper the structures and therefore higher the aspect ratio, the more difficult it is to remove the ablated particles from the discharge zone and keep the process in stable condition. Flushing can be aided by vibration of either tool or workpiece. Thus, applying ultrasonic vibration to micro EDM has proven to enhance the process significantly. The vibration is most efficiently induced via the tool or workpiece directly to the discharge zone. However, to achieve an ultrasonic vibration of the tool or workpiece, a complex vibration system that operates in resonant mode is needed. Any crucial change of the vibrating parts results in a demanding and therefore expensive adjustment of the vibrating system. With this setup, the application of ultrasonic vibration is only profitable for large scale serial production. In this work a different approach of ultrasonic superposition to the EDM is proposed. A highly focused ultrasonic vibration is induced into the dielectric in a way to directly influence the discharge zone. This indirect ultrasonic superposition can be easily applied since it is independent of the tool or workpiece geometry. Experiments are carried out to examine the effects of the indirect ultrasonic superposition on the EDM process. First results show the possibility of enhancing micro-EDM by this approach.

A REVIEW ON VIBRATION-ASSISTED EDM, MICRO-EDM AND WEDM

2019 ◽  
Vol 26 (05) ◽  
pp. 1830008 ◽  
Author(s):  
K. P. MAITY ◽  
M. CHOUBEY
Keyword(s):  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Electrode Wear ◽  
Micro Edm ◽  
Vibration Parameters ◽  
Unconventional Machining ◽  
Edm Process

Electrical discharge machining (EDM) is an unconventional machining process used for machining of hard-to-cut materials. Both EDM and micro-EDM processes are extensively used for producing dies and molds, complex cavities, and 3D structures. In recent years, researchers have intensively focused on improving the performance of both micro-EDM and EDM processes. This paper reviews the research work carried out by the researchers on vibration-assisted EDM, micro-EDM, and wire EDM. The consolidated review of this research work enables better understanding of the vibration-assisted EDM process. This study also discusses the influence of vibration parameters such as vibration frequency and amplitude on the material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR). The important issues and research gaps in the respective area of research are also presented in this paper.

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