scholarly journals Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 907 ◽  
Author(s):  
Jaber Abu Qudeiri ◽  
Ahmad Saleh ◽  
Aiman Ziout ◽  
Abdel-Hamid Mourad ◽  
Mustufa Abidi ◽  
...  
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Future Research ◽  
Process Conditions ◽  
Process Performance ◽  
Electric Discharge Machining ◽  
Electrically Conductive ◽  
Complex Shapes ◽  
Efficient Manufacturing

Electric discharge machining (EDM) is a material removal process that is especially useful for difficult-to-cut materials with complex shapes and is widely used in aerospace, automotive, surgical tools among other fields. EDM is one of the most efficient manufacturing processes and is used to achieve highly accurate production. It is a non-contact thermal energy process used to machine electrically conductive components irrespective of the material’s mechanical properties. Studies related to the EDM have shown that the process performance can be considerably improved by properly selecting the process material and operating parameters. This paper reviews research studies on the application of EDM to different grades of stainless steel materials and describes experimental and theoretical studies of EDM that have attempted to improve the process performance, by considering material removal rate, surface quality and tool wear rate, amongst others. In addition, this paper examines evaluation models and techniques used to determine the EDM process conditions. This review also presents a discussion on developments in EDM and outlines the likely trend for future research.

scholarly journals Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

2020 ◽  
Vol 10 (6) ◽  
pp. 2082 ◽  
Author(s):  
Jaber E. Abu Qudeiri ◽  
Aiman Zaiout ◽  
Abdel-Hamid I. Mourad ◽  
Mustufa Haider Abidi ◽  
Ahmed Elkaseer
Keyword(s):  
Large Scale ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Future Research ◽  
Process Conditions ◽  
Process Performance ◽  
Die Steels ◽  
Wide Range ◽  
Complex Shapes ◽  
Manufacturing Technologies

Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

A Brief Review of Experimental Investigations and Analytical Development of Powder Mixed Electric Discharge Machining (PMEDM)

2021 ◽  
Vol 106 ◽  
pp. 31-38
Author(s):  
Sovan Bhowmick ◽  
Gautam Majumdar ◽  
Asish Bandyopadhyay
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
White Layer ◽  
Thermal Characteristics ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Machined Surface ◽  
Electrically Conductive ◽  
White Layer Thickness

Powder mixed electric discharge machining (PMEDM) is a newly developed technology in which EDM is performed by mixing electrically conductive micro or nanoparticles with dielectric fluid. The electrically conductive tiny particles when come at the gap of electrode and work piece, they will begin to create spark by the induction of electrode voltage which enhances the material removal and surface finish of the machined surface. In this paper a brief review has been done on different aspects of powder mixed electric discharge machining. It is observed that the researches are done in three main directions. Firstly, experimental studies are done to show the effect of several input process parameters on responses mainly material removal rate (MRR), surface roughness and tool wear rate. Secondly, the metallurgical characteristics of the machined surface are analyzed to measure the white layer thickness and amount of powder material inclusion onto the surface. The third one is the investigation of thermal characteristics of the tool and work pieces during the machining process. In these three sections of researches, the results of the investigations have been discussed in this review. Keywords: powder mixed electric discharge machining, metallurgical characteristics, nano particles, material removal rate, surface roughness, tool wear rate, white layer thickness, thermal characteristics

Nano Graphite Powder Assisted Electric Discharge Machining Characteristics of ZM21 Magnesium Alloy

2015 ◽  
Vol 787 ◽  
pp. 406-410
Author(s):  
S. Santosh ◽  
S. Javed Syed Ibrahim ◽  
P. Saravanamuthukumar ◽  
K. Rajkumar ◽  
K.L. Hari Krishna
Keyword(s):  
Magnesium Alloy ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Zm21 Magnesium Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Magnesium alloys are used in many applications, particularly in orthopaedic implants are very difficult to machine by conventional processes because of their complex 3D structure and limited slip system at room temperature. Hence there is an inherent need for alternative processes for machining such intricate profiles. Electric Discharge Machining is growing rapidly in tool rooms, die shops and even in general shop floors of modern industries to facilitate complex machining for difficult-to-machine materials and provide better surface integrity. Therefore, the use of electric discharge machining on ZM21 magnesium alloy is attempted in this paper. Nanographite powder is added for machining zone to enhance the electrical conductivity of EDM oil by way it improves the machining performance. Machining parameters such as the current, pulse on time and pulse off time were process parameters to explore their effects on the material removal rate and tool wear rate. It is observed that, an increased material removal rate was due to the enhanced electrical and thermal conductivity of the EDM oil.

Electric discharge sawing of hybrid metal matrix composites

2015 ◽  
Vol 231 (10) ◽  
pp. 1775-1782 ◽  
Author(s):  
Ravinder Kumar ◽  
Inderdeep Singh
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Debris Accumulation ◽  
Carbon Particles ◽  
Hybrid Metal Matrix Composite ◽  
Sawing Process

Electric discharge sawing process is a novel process for the enrichment of capabilities of electric discharge machining. The process has been developed to cut materials at greater depths where the effect of flushing becomes ineffective. During electric discharge machining at greater depths, ineffective flushing prevents debris and carbon particles from leaving the machining zone and gets accumulated in the sparking zone reducing the spark efficiency. This reduces material removal rate and causes arcing or short circuiting which may damage the workpiece and/or tool surface. In the present experimental endeavor, a new process capable of preventing debris accumulation during machining of slots at large depth and subsequently increasing material removal rate has been developed. In the process, a reciprocating motion is given to the tool blade similar to the power hacksaw blade. An experimental investigation based on central composite design has been conducted on hybrid metal matrix composite to evaluate the effect of input parameters on material removal rate and tool wear rate. It has been found that the electric discharge sawing process is quick and effective as compared to the conventional cutting process.

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