scholarly journals Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode

2021 ◽  
Vol 11 (5) ◽  
pp. 2084 ◽  
Author(s):  
Kamonpong Jamkamon ◽  
Pichai Janmanee
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Side Wall ◽  
Machining Process ◽  
Hole Drilling ◽  
Electrode Wear ◽  
Deep Hole ◽  
Cylindrical Electrode ◽  
Machining Performance ◽  
Deep Hole Drilling

The performance of electrical discharge machining for drilling holes decreases with machining depth because the conventional flushing and electrode cannot completely eliminate debris particles from the machining area. In this study, a modified electrode for self-flushing in the electrical discharge machining process with a step cylindrical shape was designed to improve machining performance for deep hole drilling. The experimental results of the step cylindrical electrode showed that the material removal rate increased by approximately 215.7%, 203.8%, and 130.4%, and the electrode wear ratio decreased by approximately 47.2%, 63.1%, and 37.3%, when compared with a conventional electrode for the diameters of 6, 9, and 12 mm, respectively. In addition, the gap clearance and concavity of the side wall of the drilled hole was reduced with the step cylindrical electrode. The limited high flank of the electrode led to an increase in the escape area of the debris that was partially removed from the machining area, and the limited secondary spark on the side wall of the electrode resulted in a reduction in machining time.

Evaluation of Electrical Discharge Machining Performance on Al (6351)–SiC–B4C Composite

2019 ◽  
pp. 109-124
Author(s):  
Uthayakumar M. ◽  
Suresh Kumar S. ◽  
Thirumalai Kumaran S. ◽  
Parameswaran P.
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machined Surface ◽  
Output Performance ◽  
B4c Particles

Electrical discharge machining (EDM) process is a non-conventional machining process used for the material which are difficult to machine. In this research work, an attempt has been made to determine the influence of Boron Carbide (B4C) particles on the machinablity of the Al (6351) alloy reinforced with 5 wt. % Silicon Carbide (SiC) Metal Matrix Composite (MMC) through EDM. Influence of machining parameters such as pulse current (I), pulse on time (Ton), duty factor (τ), and gap voltage (V) on affecting the output performance characteristics namely Electrode Wear Ratio (EWR), Surface Roughness (SR) and Power Consumption (PC) which are studied. The result shows that the addition of B4C particles significantly affects the machinablity of the composite, with a contribution of 1.6% on EWR, 3.5% on SR and 19.8% on PC. The crater, recast layer formation, and Heat Affected Zone (HAZ) in the machined surface of the composite are also reported in detail.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

2020 ◽  
Vol 235 (1-2) ◽  
pp. 125-133
Author(s):  
Omer Eyercioglu ◽  
Kursad Gov
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Magnesium Content ◽  
Machining Process ◽  
Electrode Wear ◽  
Ti Alloy ◽  
Ti Alloys ◽  
Mg Content

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

A Mathematical Model to Describe the Inner Contour of Moineau Stators

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Ekrem Oezkaya ◽  
Moritz Fuss ◽  
Dirk Biermann
Keyword(s):  
Mathematical Model ◽  
Machining Process ◽  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Hole Drilling Method ◽  
Current State ◽  
Drilling Method ◽  
Large Length

Abstract Bore holes with a large length to diameter ratio of up to l/d = 100 are typically produced using the single-tube deep hole drilling method also named BTA (Boring and Trepanning Association) deep hole drilling method. However, there are various technical applications requiring deep, complex, epitrochoid-similar and helical inner contours, such as stators used in Moineau motors and pumps. According to the current state of the art, epitrochoid-similar contours for small diameters with large drilling depths can only be produced using a special machining process which is referred to a chamber-boring process. In this paper, a developed mathematical model will be presented that describes the epitrochoid-similar contour exactly. This allows the determination of the position-dependent speed and acceleration of the tool, which are necessary for designing the joints and components of the tool system. In addition, this mathematical model can be used for a subsequent Laplace-transformation, so that could be used for a further optimization of the process dynamic in the future.

Investigation on the Effect of Multi Wall Carbon Nano Tubes in Wire Electrical Discharge Machining of Hybrid Metal Matrix Composites

2014 ◽  
Vol 592-594 ◽  
pp. 456-460
Author(s):  
S. Ramesh ◽  
N. Natarajan ◽  
Vijayan Krishnaraj ◽  
K. Sathish Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Matrix Composites ◽  
Machining Performance ◽  
Carbon Nano Tubes

Wire Electrical Discharge Machining (WEDM) is an very accurate non-traditional machining process for producing parts with accurate dimensions and complex shapes. The performance of WEDM is measured by evaluating the parameters like Material Removal Rate (MRR), Surface Roughness (Ra), cracks, voids, pores and recast layer. In this paper, an attempt is made to improve the machining performance by adding multi wall carbon nanotube (MWCNT) with dielectric fluid. The MRR, Ra and surface characteristics are compared with surface that is machined using dielectric fluid with and without MWCNT. The results show that addition of MWCNT improves the MRR and surface finish.

Electrode Tool Wear at Electrical Discharge Machining

2012 ◽  
Vol 504-506 ◽  
pp. 1189-1194 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Margareta Coteaţă ◽  
Lorelei Gherman ◽  
...  
Keyword(s):  
Cross Section ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Experimental Tests ◽  
Machining Process ◽  
Electrode Wear ◽  
Electrical Discharges ◽  
Workpiece Material ◽  
Electrode Tool ◽  
Theoretical Considerations

As consequence of the development of electrical discharge machining process, the electrode is affected by wear; knowing the evolution of the electrode wear, a better estimation of its service life is possible. It is expected that the electrode wear depends on the energy of the electrical discharges and the mass of the electrode. It is known also that the nature of the workpiece material exerts influence on the evolution of the electrode wearing process. In the paper, some theoretical considerations are used to highlight the above mentioned aspects. A set of experimental tests was designed and developed in order to highlight the influence exerted by the nature of the workpiece material and by the size of the cross section of the electrode, respectively, on the electrode wear. Empirical mathematical models corresponding to the evolution of the electrode wear were established.

Modeling and Optimization of Micro Electro Discharge Machining Process: A Review

2012 ◽  
Vol 622-623 ◽  
pp. 590-594 ◽  
Author(s):  
P. Sivaprakasam ◽  
P. Hariharen ◽  
S. Kathikheyen ◽  
S. Balusamy
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Work Piece ◽  
Machining Performance ◽  
Micro Electrical Discharge Machining ◽  
Electro Discharge Machining ◽  
Short Period

Micro Electrical discharge machining (µEDM) is an electro thermal process, the cutting force is negligibly small and material removal occurs irrespective of hardness of work piece material .Micro electrical discharge machining process is capable of machining of complex shape, which is difficult to machine in conventional machining process. Last decade, the EDM process involved demand for machining requirements with short period. Since the major risk of wire breakage, deflections of electrodes were affecting the performance accuracy of EDM operation. This paper describe about a comprehensive review of micro electro discharge machining process and its process optimization techniques used for last 10 years. Micro electro discharge machining has more important given to difficult to machine materials. In order to improve the surface integrity and performance of process, need to select proper process parameters. It reports on the Micro EDM research involving the optimization of the process parameters surveying the influence of the various factors affecting the machining performance and productivity.

An Experimental Study of the Phenomenon of Surface Alloying by EDM Process Using Inconel Tool Electrode

2013 ◽  
Author(s):  
Sanjeev Kumar
Keyword(s):  
Experimental Study ◽  
Surface Properties ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Plasma Channel ◽  
Machining Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Surface Alloying ◽  
Machining Conditions

Electrical Discharge Machining (EDM) has emerged as a very important machining process due to its numerous advantages. It is extensively used by the die and toolmaking industry for the accurate machining of complex internal profiles. Although EDM is essentially a material removal process, it has been used successfully for improving the surface properties of the work materials after machining. As the dissolution of the electrode takes place during the process, some of its constituents may alloy with the machined surface under appropriate machining conditions. Additive powders in the dielectric medium may form part of the plasma channel in the molten state and produce similar alloying effect. The breakdown of the hydrocarbon dielectric under intense heat of the spark contributes carbon to the plasma channel. Sudden heating and quenching in the spark region also alters the surface properties. This paper reports the results of an experimental study into electrical discharge machining of H13 hot die steel with Inconel (an alloy of chromium, nickel and iron) tool electrode under machining conditions favouring high electrode wear. The results show improvement in micro-hardness after machining by as much as 88%. Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) analysis of the machined surfaces show transfer of chromium and nickel from the tool electrode. Both these elements form intermetallic compounds as well as solid solution with iron and strengthen it. It was found that percentage of chromium increased from 5.39% to 6.52% and that of nickel increased from 0.19% to 4.87%. The favourable machining conditions for surface alloying were found to be low value of peak current, shorter pulse on-time, longer pulse off-time and negative polarity of the tool electrode.

Research of Machining Process on 17-4PH Stainless Steel Superfine Deep-Hole Drilling

2014 ◽  
Vol 633-634 ◽  
pp. 688-692 ◽  
Author(s):  
Zhan Feng Liu ◽  
Han Chen Wang
Keyword(s):  
Stainless Steel ◽  
Wall Thickness ◽  
Machining Process ◽  
New Method ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Gun Drill

Through the analysis of superfine deep-hole drilling process, we used the combination of gun drill and BTA deep-hole drilling process for 17-4PH (0Cr17Ni4Cu4Nb) stainless steel deep-hole drilling test. We measured wall thickness point by point, and calculated the conversion of the eccentricity in a deviation axis line. Which fully embodies the advantage of this process for stainless steel 17-4PH, and provides a new method in super hardness material deep-hole drilling field.

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