scholarly journals On Electrical Discharge Machining of Non-Conductive Ceramics: A Review

Technologies ◽  
2019 ◽  
Vol 7 (3) ◽  
pp. 55 ◽  
Author(s):  
Marina Volosova ◽  
Anna Okunkova ◽  
Pavel Peretyagin ◽  
Yury A. Melnik ◽  
Natalya Kapustina
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Secondary Phase ◽  
Scientific Revolutions ◽  
Relevant Today ◽  
Potential Applications ◽  
Conductive Ceramics ◽  
3D Printed ◽  
Full Shift

The inability of ceramic and nanoceramic processing without expensive diamond tools and with a high-material-removal rate hampers the scope of its potential applications and does not allow humanity to make a full shift to the sixth technological paradigm associated with Kuhn scientific revolutions and Kondratieff’s waves and restrains the growth of the economy. The authors completed a review on the research state of ceramic and nanoceramic processing by electrical discharge machining, which is possibly solved by two principal approaches associated with the usage of standard commercially available machine tools. The first approach is related to the introduction of expensive secondary phase; the second approach proposes initiate processing by adding auxiliary electrodes in the form of coating, suspension, aerosol, or 3D-printed layer based on the components of silver, copper, or graphite in combination with an improved dielectric oil environment by introducing graphite or carbon nanoparticles, which is hugely relevant today.

Parametric Analysis of Micro Electrical Discharge Milling Process of Non-Conductive Silicon Carbide

2015 ◽  
Vol 651-653 ◽  
pp. 744-749 ◽  
Author(s):  
Florian Zeller ◽  
Nirdesh Ojha ◽  
Claas Müller ◽  
Holger Reinecke
Keyword(s):  
Silicon Carbide ◽  
Electrical Discharge ◽  
Parametric Analysis ◽  
High Performance ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Milling Process ◽  
Tool Materials ◽  
Conductive Ceramics ◽  
Main Effects

Silicon carbide (SiC) is a high performance ceramic material which is increasingly used in applications which demand for high temperature stable materials. The microstructuring of this material in its sintered state is a challenge for conventional machining methods due to its extraordinary mechanical properties. To overcome these limitations the process of electrical discharge machining (EDM) was modified with a so called assisting electrode (AE) to enable the structuring of non-conductive ceramics such as SiC. This paper presents a parametric analysis of micro electrical discharge milling process of non-conductive SiC for two different tool materials, tungsten carbide (WC) and copper (Cu). A full factorial design with four factors was conducted. The significant factors are shown with main effects plots. Two sets of optimized parameters for maximum material removal rate (MRR) and minimum tool wear rate (TWR) for both tool materials are presented. Hardness and surface roughness are measured and compared to the non-machined material.

Effect of Gap Voltage and Pulse-On Time on Material Removal Rate for Electrical Discharge Machining of Al2O3

2015 ◽  
Vol 1115 ◽  
pp. 3-6 ◽  
Author(s):  
M.A. Moudood ◽  
Abdus Sabur ◽  
Mohammad Yeakub Ali ◽  
I.H. Jaafar
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Carbon Layer ◽  
Peak Current ◽  
Conductive Ceramics ◽  
Pulse On Time

Electrical discharge machining (EDM) is a non-conventional machining technique which can be used to machine non-conductive ceramics. This technique removes materials from the workpiece by thermal energy exerted from series of electrical sparks. Using copper foil as assisting electrode (AE), machining of Al2O3 is done successfully. In this investigation, experiments were performed to study the effect of gap voltage and pulse-on time on material removal rate (MRR) for EDM of Al2O3. The results showed that the lowest and the highest values of gap voltage were 12 V and 14 V, respectively, with a fixed peak current of 1.1 A and pulse-on time of 8 μs. Beyond these two voltage values, material cannot be removed due to insufficient pyrolytic carbon layer generation. Similarly, pulse-on time is varied from 6 μs to 8 μs when gap voltage is fixed at 14 V and peak current at 1.1 A. MRR, in this case, is increased almost 20 times from a lowest value of 0.006 mm3/min to a highest value of 0.119 mm3/min for the specified gap voltage and pulse-on time.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

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 The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

2020 ◽  
Vol 10 (1) ◽  
pp. 401-407
Author(s):  
Yanuar Rohmat Aji Pradana ◽  
Aldi Ferara ◽  
Aminnudin Aminnudin ◽  
Wahono Wahono ◽  
Jason Shian-Ching Jang
Keyword(s):  
Surface Roughness ◽  
Metallic Glasses ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Recast Layer ◽  
Surface Evaporation ◽  
Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

scholarly journals On Adaptive Control for Electrical Discharge Machining Using Vibroacoustic Emission

Technologies ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 96 ◽  
Author(s):  
Yury Melnik ◽  
Mikhail Kozochkin ◽  
Artur Porvatov ◽  
Anna Okunkova
Keyword(s):  
Adaptive Control ◽  
Control System ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hard Alloys ◽  
Monitoring And Control ◽  
Working Zone ◽  
Conductive Ceramics ◽  
And Control ◽  
Adequate Data

The article is related to the research of the parameters of vibroacoustic emission for development of the monitoring and adaptive control system for electrical discharge machining. The classical control system based on a response of electrical parameters does not give an adequate data in the cases of a new class of materials processing as conductive ceramics reinforced by conductive nano additives and carbon nanotubes and whiskers. The idle pulses, which are working on the destruction of the erosion products in the gap, count as working pulses. The application of the monitoring and control tools based on vibroacoustic emission gives adequate data about conditions in the working zone. The developed system is available to count only impulses involved in working on the destruction of the workpiece. The experiments were conducted on the samples of materials with a low melting point as austenitic steel and aluminum alloy, and hard alloys. The records of vibroacoustic signals were analyzed for detection of the monitoring and adaptive control criteria.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

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