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.

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.

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.

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.

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.

Effects of Combined Ultrasonic Vibration during the Sinking EDM Process for Cemented Carbide

2009 ◽  
Vol 76-78 ◽  
pp. 657-663 ◽  
Author(s):  
Chaiya Praneetpongrung ◽  
Yasushi Fukuzawa ◽  
Shigeru Nagasawa
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Cemented Carbide ◽  
Electrode Wear ◽  
Machining Properties ◽  
Edm Process

In recent years, to improve the electrical discharge machining properties, several trials have been applied with the ultrasonic vibration system which was combined on the sinking electrical discharge machine. In this paper, the effects of the ultrasonic vibration were investigated with the designed sinking EDM machine. Some experimental parameters of tool electrode polarity, rotational workpiece speed and directions were examined during the sinking EDM process on the cemented carbide material of G5. Material removal rate, electrode wear ratio and surface roughness were estimated as the machining properties under finishing machining conditions. The experiments were carried out on ultrasonic longitudinal frequency 59 kHz and electrode spindle till 1,000 rpm. Two rotational apparatuses were used simultaneously on the opposite rotational direction during discharge machining. The discharge conditions were estimated with the waveforms analysis. As the results, the EDM device system which was combined ultrasonic vibration, improved the material removal rate and surface roughness of the EDMed workpiece.

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.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

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