scholarly journals Micro-Drilling of Sapphire Using Electro Chemical Discharge Machining

Micromachines ◽  
2020 ◽  
Vol 11 (4) ◽  
pp. 377
Author(s):  
Chao-Ching Ho ◽  
Jia-Chang Chen
Keyword(s):  
Material Removal ◽  
Electrolyte Concentration ◽  
Tool Electrode ◽  
Machining Efficiency ◽  
Electrode Rotation ◽  
Electrochemical Discharge Machining ◽  
Front End ◽  
Micro Drilling ◽  
Hard And Brittle Materials ◽  
Jet Nozzle

Electrochemical discharge machining (ECDM) refers to a non-traditional machining method for performing effective material removal on non-conductive hard and brittle materials. To increase the ECDM machining efficiency, traditionally, the method of increasing the machining voltage or increasing the electrolyte concentration is used. These methods can also cause overcut reaming of the drilled holes and a rough surface on the heat affected area. In this study, an innovative combinational machining assisted method was proposed and a self-developed coaxial-jet nozzle was used in order to combine two assisted machining methods, tool electrode rotation and coaxial-jet, simultaneously. Accordingly, the electrolyte of the machining area was maintained at the low liquid level and the electrolyte was renewed at the same time, thereby allowing the spark discharge to be concentrated at the contact surface between the front end of the tool electrode and the machined material. In addition, prior to the machining and micro-drilling, the output of the machining energy assisted mechanism was further controlled and reduced. For the study disclosed in this paper, experiments were conducted to use different voltage parameters to machine sapphire specimens of a 640 μm thickness in KOH electrolyte at a concentration of 5 M.

Experimental Investigation of Drilling Incorporated Electrochemical Discharge Machining

2014 ◽  
Author(s):  
Baoyang Jiang ◽  
Shuhuai Lan ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Drilling Process ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Drilling

Electrochemical discharge machining (ECDM) is a non-conventional micromachining technology, and is highlighted for non-conductive brittle materials. However, the outcomes of ECDM have many restrictions in application due to limitations on efficiency, accuracy, and machining quality. In this paper, a drilling incorporated ECDM process is presented and analyzed to enhance material removal rate in ECDM drilling process. Incorporating micro-drilling into ECDM significantly increases the rate of material removal, especially in deep hole drilling. As fundamentals of the machining process, material removal mechanisms have been investigated to account for the increment in material removal rate by incorporating micro-drilling. Vibration of tool electrode, induced by a piezo-actuator, was introduced to further enhance material removal rate. Quantitative studies were conducted to determine the appropriate process parameters of drilling incorporated ECDM with tool vibration.

Machining Characteristics of IN718 by EDM with Cooled Electrode and Vibration of the Workpiece

2020 ◽  
Vol 996 ◽  
pp. 131-136
Author(s):  
Yao Li ◽  
Cheng Cui ◽  
Bengang Lin ◽  
Li Li
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Cryogenic Cooling ◽  
Tool Electrode ◽  
Machining Efficiency ◽  
Electrical Erosion ◽  
Machining Characteristics ◽  
Edm Process ◽  
Process Material

Inconel718 has been widely used in various fields for its good performance, but it is difficult to machine with traditional machining methods. Electrical discharge machining is an alternative competitive process to machine Nickel-based alloys by electrical erosion. In order to improve reduce the electrode loss and improve the machining efficiency, the horizontal ultrasonic vibration of the workpiece and the cryogenic cooling of the tool electrode were applied into the EDM process. Material removal efficiency, surface roughness, surface topography, and microhardness have been characterized.

Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB2in situ composites using the Entropy–VIKOR method

2020 ◽  
Vol 234 (10) ◽  
pp. 1311-1322 ◽  
Author(s):  
S Chandrasekhar ◽  
NBV Prasad
Keyword(s):  
Applied Voltage ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Entropy Method ◽  
Machining Parameters ◽  
Vikor Method ◽  
Electron Microscopic ◽  
Micro Drilling ◽  
Response Optimization

This article describes the multi-response optimization of electrochemical machining operating parameters such as voltage, concentration of the electrolyte, and current to maximize the rate of material removal in addition to minimize the over cut and delamination at the same time in micro-drilling of AA6061-TiB2 in situ composite. A novel Entropy–VIKOR method is applied to handle such mutually conflicting responses. The weight of each response is computed from the entropy method, and VIKOR method is used to rank the various levels of parameters. This method yields the combination of 2 mol of electrolyte concentration, 16 V of applied voltage, and 4 A of current as optimal parameters to minimize the over cut and delamination in addition to maximize the rate of material removal at the same time. This optimal process-governing parameters satisfied the conditions for compromising solution such as acceptable advantage and acceptable stability condition. The response graph illustrates that, of the parameters investigated, electrolyte concentration has the greatest effect on the VIKOR index, followed by applied voltage and current. Scanning electron microscopic analysis illustrates that the radius of the hole is equal throughout the periphery, except for one instance of micro-delamination.

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.

Effect of Arc Discharge Pressure on Discharge Current in EDM

2008 ◽  
Vol 381-382 ◽  
pp. 451-454
Author(s):  
Atsutoshi Hirao ◽  
S. Tai ◽  
H. Takezawa ◽  
Naotake Mohri ◽  
Kazuro Kageyama ◽  
...  
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Vibration Sensor ◽  
Work Piece ◽  
Tool Electrode ◽  
Discharge Pressure ◽  
Current Behavior

In electrical discharge machining (EDM), an electrical discharge occurs between a tool electrode and a work-piece, and removal of materials is carried out by vaporized explosion between the electrode and the work-piece. However, the mechanism of material removal in EDM is not well understood. In order to clarify this issue, the acoustic emission (AE) method has been applied to examine the force of explosion, and the Schlieren visualization method has been applied to observe the explosion. In this study, we investigate the effect of discharge current behavior on the occurrence of the AE waves by means of an optical fiber vibration sensor.

scholarly journals Grey Relational Analysis Optimization of Input Parameters for Electrochemical Discharge Drilling of Silicon Carbide by Gunmetal Tool Electrode

2020 ◽  
Vol 44 (4) ◽  
pp. 239-249
Author(s):  
Pravin Pawar ◽  
Amaresh Kumar ◽  
Raj Ballav
Keyword(s):  
Silicon Carbide ◽  
Grey Relational Analysis ◽  
Electrolyte Concentration ◽  
Research Work ◽  
Machining Process ◽  
Advanced Technology ◽  
Tool Electrode ◽  
Relational Analysis ◽  
Electrochemical Discharge ◽  
Grey Relational

The electrochemical discharge machining process (ECDM) is a hybrid advanced technology integrated with electrochemical and electro-discharge processes has used for the manufacturing of non-conducting along with conducting materials. The silicon carbide is non-conducting material which has widely used in various fields such as automobile, aviation, medical, nuclear reactor, and missile. The machining of silicon carbide is a challenging task by using non-conventional along with conventional machining processes due to its physical properties. The current research work shows the machining of Silicon carbide material by using fabricated ECDM machine setup with gunmetal tool material. The Taguchi L27 orthogonal array technique is applied for experimental work. The grey relational analysis optimization is applied for the investigation of optimum input factors for better output responses. The input process factors like electrolyte concentration, applied voltage, and rotation of tool and outcome results such as machined depth and the diameter of hole were checked after drilling of silicon carbide material. The experimental results indicate the electrolyte concentration is the leading factor for diameter of hole and depth of machined hole subsequent to voltage and tool rotation.

scholarly journals Experimental study on high-efficiency DC short electric arc milling of titanium alloy Ti6Al4V

2021 ◽  
Author(s):  
Zongjie Zhou ◽  
Kai Liu ◽  
Yan Xu ◽  
Jianping Zhou ◽  
Lizhong Wang
Keyword(s):  
Titanium Alloy ◽  
Electrode Material ◽  
Material Removal ◽  
Electrode Materials ◽  
Arc Discharge ◽  
Specific Energy Consumption ◽  
Base Material ◽  
Electric Arc ◽  
Tool Electrode ◽  
Q235 Steel

Abstract Short electric arc milling (SEAM) is an efficient electrical discharge machining method, especially for the efficient removal of difficult-to-machine conductive materials with high hardness, high toughness, and wear resistance. In this study, titanium alloy Ti–6Al–4V is used as the research object to conduct machining experiments. The material removal mechanism of SEAM technology is studied using a DC power supply and different tool electrode materials (copper, graphite, Q235 steel, and titanium). The energy distribution of the discharge gap is analyzed using a data acquisition system and a high-speed camera. The arc is found to move with the spindle rotation in the process of arc discharge, and multi-point discharge occurs in the process of single-arc discharge. The voltage and current waveforms and the radius of the etched particles during the experiment were counted, the material removal rate (MRR) and relative tool wear rate (RTWR) are calculated, and the surface and cross-section micromorphology and hardness are analyzed. The experimental results show that when the electrode material is graphite, the maximum feed rate is 650 mm/min, the MRR can reach 17268 mm3/min, the ideal maximum MRR is more than 65000 mm3/min, and the RTWR is only 1.27%. When the electrode material is Q235 steel, the minimum surface roughness is 35.04 µm, and this material has good stability under different input voltages. When the electrode material is copper, the hardness of the resolidified layer is close to that of the base material, which is beneficial for further processing. The lowest specific energy consumption is 18.26 kJ/cm3 when titanium is used as the electrode material.

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