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.

scholarly journals Recent Advances and Perceptive Insights into Powder-Mixed Dielectric Fluid of EDM

Micromachines ◽  
2020 ◽  
Vol 11 (8) ◽  
pp. 754 ◽  
Author(s):  
Asarudheen Abdudeen ◽  
Jaber E. Abu Qudeiri ◽  
Ansar Kareem ◽  
Thanveer Ahammed ◽  
Aiman Ziout
Keyword(s):  
Tool Wear ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Dielectric Fluids ◽  
Advanced Machining ◽  
Low Efficiency ◽  
Edm Process ◽  
Powder Mixed Edm

Electrical discharge machining (EDM) is an advanced machining method which removes metal by a series of recurring electrical discharges between an electrode and a conductive workpiece, submerged in a dielectric fluid. Even though EDM techniques are widely used to cut hard materials, low efficiency and high tool wear remain remarkable challenges in this process. Various studies, such as mixing different powders to dielectric fluids, are progressing to improve their efficiency. This paper reviews advances in the powder-mixed EDM process. Furthermore, studies about various powders used for the process and its comparison are carried out. This review looks at the objectives of achieving a more efficient metal removal rate, reduction in tool wear, and improved surface quality of the powder-mixed EDM process. Moreover, this paper helps researchers select suitable powders which are exhibiting better results and identifying different aspects of powder-mixed dielectric fluid of EDM.

Current Research Trends on Dry, Near-Dry and Powder Mixed Electrical Discharge Machining

2011 ◽  
Vol 264-265 ◽  
pp. 956-961 ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M.M. Rahman ◽  
M.M. Noor ◽  
K. Kadirgama ◽  
M.A. Maleque
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Trends ◽  
Dielectric Fluid ◽  
Electrically Conductive ◽  
Conventional Machining ◽  
Edm Process ◽  
Dies And Moulds

Electrical discharge machining (EDM) technique has been widely used in modern metal working industry for producing complex cavities in dies and moulds, which are otherwise difficult to create by conventional machining. The process has the advantage of being able to machine hardened tool steels. However, its low machining efficiency and poor surface finish restricted its further applications. To address these problems, one relatively new technique used to improve the efficiency and surface finish is EDM in the presence of powder suspended in the dielectric fluid. Powder mixed electric discharge machining (PMEDM) is one of the recent innovations for the enhancement of capabilities of EDM process. In PMEDM, the electrically conductive powder is mixed in the dielectric fluid of EDM, which reduces the insulating strength of the dielectric fluid and increases the spark gap between the tool and workpiece. As a result, the process becomes more stable, thereby, improving the material removal rate (MRR) and surface finish. Moreover, the surface develops high resistance to corrosion and abrasion. This paper presents the current research trends on dry, near dry EDM and review on research carried out in the area of PMEDM.

Analysis of Micro-EDM Process of D3 Die-Steel Employing NaNO3 Mixed Deionised Water-An Optimal Approach

2019 ◽  
Vol 11 (4) ◽  
pp. 50-66
Author(s):  
Golam Kibria ◽  
Ishwer Shivakoti ◽  
B.B. Pradhan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Qualitative Assessment ◽  
Gray Relational Analysis ◽  
Dielectric Fluid ◽  
Micro Edm ◽  
Die Steel ◽  
Edm Process

In micro-electrical discharge machining, the selection of proper dielectric fluid is one of the important issues regarding the machining rate, geometrical accuracy, as well as surface profiles obtained. Each type of dielectric fluid has their own values of viscosity, flash point, cooling rate and compositions. In addition, depending on the resistivity and other characteristics, dielectric fluid has its own value of dielectric strength. In the present article, an attempt has been made to carryout experimentation during micro-EDM process of D3 die-steel employing NaNO3 salt mixed deionised water. Taguchi-GRA (gray relational analysis) based experimental scheme and optimization technique has been applied to analyze the process parameters to optimize the material removal rate, tool wear rate, overcut and taper of micro-hole generated. Optical microscopic images were also analysed for qualitative assessment of process parameters.

scholarly journals Investigation of the Effect of Nano Powder Mixed Dielectric on EDM Process

2020 ◽  
Vol 38 (3A) ◽  
pp. 295-307
Author(s):  
Rasha R. Elias
Keyword(s):  
Aluminum Oxide ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Dielectric Fluid ◽  
Tool Wear Rate ◽  
Powder Concentration ◽  
Nano Powder ◽  
Edm Process

In this paper, Artificial Neural Network was adopted to predict the effect of current, the concentration of aluminum oxide (Al2O3) and graphite Nanopowders in dielectric fluid for the machining of Carbon steel 304 using Electrical Discharge Machining (EDM). The process variables were utilized to find their effect on Material Removal Rate (MRR), Surface Roughness (SR), and Tool Wear Rate (TWR). It was revealed from the experimental work that the addition of aluminum oxide and graphite Nanopowders into dielectric fluid maximizing MRR, minimized the SR and TWR at various variables. Minitab software was used in the design of experiments. Analysis of the process outputs of EDM indicates that graphite powder concentration greatly influencing SR also the discharge current whereas the current and Nanopowders concentration has more percentage of influence on the TWR and MRR.

scholarly journals Investigation into effects/Investigating the effects of titanium powder concentrations mixed in dielectric fluid on material machining removal and surface roughness of SKD61 steel after electrical discharge machining by reverse electrode polarity

2015 ◽  
Vol 18 (2) ◽  
pp. 43-51
Author(s):  
Long Tien Banh ◽  
Cuong Ngo ◽  
Phan Huu Nguyen
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Material Removal ◽  
Titanium Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Electrode Polarity ◽  
Edm Process

Electrical discharge machining (EDM) has found widespread applications in tool , mold and aerospace industries. Therefore, enhancement of the quality of the EDM process has become a major research concern. In this paper, the effect of various titanium powder concentrations on the Material Removal Rate (MRR), tool wear rate (TWR), surface roughness (Ra) in powder mixed electrical discharge machining (PMEDM) have been studied. The workpiece is SKD61steel and electrode made from copper with reverse polarity were used in experimental study. The results showed that titanium powder mixed into the dielectric fluid of EDM can enhance MRR without increasing TWR and Ra.

scholarly journals Effect of Carbon Nano Tube Addition with Dielectric Fluid in Die Sink EDM

2019 ◽  
Vol 9 (2) ◽  
pp. 1462-1468
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Working Fluid ◽  
Dielectric Fluid ◽  
Machining Processes ◽  
Carbon Nano Tubes ◽  
Series Of Experiments ◽  
Novel Applications ◽  
Carbon Nano Tube ◽  
Edm Process

Advance machining processes such as Electrical Discharge Machining (EDM) have been extensively discussed these days due to its novel applications in industry. Series of experiments are conducted across various researchers for performance improvement of the EDM process. Mixing micro/nano powder in working fluid for better result of material removal rate is one of the developments in conventional EDM process, known as Powder Mixed EDM. Many Researchers got successes in getting mirror like surface finish in PMEDM at low energy level, but still there will be improvements are possible by using Nano powders. Due to excellent performance in dielectric and better physical properties of the Carbon Nano Tubes (CNT’s), there is need of generalization of CNT based Powder Mixed Electric Discharge Machining (CNT-PMEDM) to increase industrial application. But less work has been reported in NPMEDM, this paper aim is to discuss all CNT’s based experimental investigation in Die Sink EDM process and its future scope to help the researchers for further development in it. In this paper details about Carbon Nano Tube and its applications as additives in EDM process to get better results are presented which helps for finding research gap and future scope in CNT-PMEDM process.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

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.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

scholarly journals Multi-Objective Optimization of Process Parameters for Powder Mixed Electrical Discharge Machining of Inconel X-750 Alloy Using Taguchi-Topsis Approach

2021 ◽  
Vol 71 (1) ◽  
pp. 1-18
Author(s):  
Basha Shaik Khadar ◽  
Raju M. V. Jagannadha ◽  
Kolli Murahari
Keyword(s):  
Boron Carbide ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

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