Micro-electrical Discharge Machining Processes

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.

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Accuracy improvement in nanographite powder-suspended dielectric fluid for micro-electrical discharge machining processes

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-011-3152-6 ◽

2011 ◽

Vol 56 (1-4) ◽

pp. 143-149 ◽

Cited By ~ 38

Author(s):

Gunawan Setia Prihandana ◽

Muslim Mahardika ◽

M. Hamdi ◽

Y. S. Wong ◽

Kimiyuki Mitsui

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Dielectric Fluid ◽

Machining Processes ◽

Accuracy Improvement ◽

Micro Electrical Discharge Machining

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A Multiobjective Genetic-Algorithm-Based Optimization of Micro-Electrical Discharge Drilling

Research Anthology on Multi-Industry Uses of Genetic Programming and Algorithms ◽

10.4018/978-1-7998-8048-6.ch035 ◽

2021 ◽

pp. 676-698

Author(s):

Deepak Rajendra Unune ◽

Amit Aherwar

Keyword(s):

Genetic Algorithm ◽

Process Parameters ◽

Inconel 718 ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Machining Processes ◽

Micro Electrical Discharge Machining ◽

Electrical Discharge Drilling ◽

Machining Rate

Inconel 718 superalloy finds wide range of applications in various industries due to its superior mechanical properties including high strength, high hardness, resistance to corrosion, etc. Though poor machinability especially in micro-domain by conventional machining processes makes it one of the “difficult-to-cut” material. The micro-electrical discharge machining (µ-EDM) is appropriate process for machining any conductive material, although selection of machining parameters for higher machining rate and accuracy is difficult task. The present study attempts to optimize parameters in micro-electrical discharge drilling (µ-EDD) of Inconel 718. The material removal rate, electrode wear ratio, overcut, and taper angle have been selected as performance measures while gap voltage, capacitance, electrode rotational speed, and feed rate have been selected as process parameters. The optimum setting of process parameters has been obtained using Genetic Algorithm based multi-objective optimization and verified experimentally.

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Golam Kibria, Muhammad P. Jahan, and B. Bhattacharyya (Eds), Micro-electrical Discharge Machining Processes Technologies and Applications

Journal of Micromanufacturing ◽

10.1177/2516598419842449 ◽

2019 ◽

Vol 2 (1) ◽

pp. 79-79

Author(s):

A. Senthil Kumar

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Machining Processes ◽

Micro Electrical Discharge Machining

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A Multiobjective Genetic-Algorithm-Based Optimization of Micro-Electrical Discharge Drilling

Handbook of Research on Emergent Applications of Optimization Algorithms - Advances in Business Information Systems and Analytics ◽

10.4018/978-1-5225-2990-3.ch031 ◽

2018 ◽

pp. 728-749

Author(s):

Deepak Rajendra Unune ◽

Amit Aherwar

Keyword(s):

Genetic Algorithm ◽

Process Parameters ◽

Inconel 718 ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Machining Processes ◽

Micro Electrical Discharge Machining ◽

Electrical Discharge Drilling ◽

Machining Rate

Inconel 718 superalloy finds wide range of applications in various industries due to its superior mechanical properties including high strength, high hardness, resistance to corrosion, etc. Though poor machinability especially in micro-domain by conventional machining processes makes it one of the “difficult-to-cut” material. The micro-electrical discharge machining (µ-EDM) is appropriate process for machining any conductive material, although selection of machining parameters for higher machining rate and accuracy is difficult task. The present study attempts to optimize parameters in micro-electrical discharge drilling (µ-EDD) of Inconel 718. The material removal rate, electrode wear ratio, overcut, and taper angle have been selected as performance measures while gap voltage, capacitance, electrode rotational speed, and feed rate have been selected as process parameters. The optimum setting of process parameters has been obtained using Genetic Algorithm based multi-objective optimization and verified experimentally.

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Recent Patents on Micro-EDM Milling

Recent Patents on Mechanical Engineering ◽

10.2174/2212797613666200213120209 ◽

2020 ◽

Vol 13 (3) ◽

pp. 219-229

Author(s):

Baocheng Xie ◽

Jianguo Liu ◽

Yongqiu Chen

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Three Dimensional ◽

Processing Method ◽

Electrode Wear ◽

Micro Edm ◽

Processing Efficiency ◽

Processing Methods ◽

Machining Quality ◽

Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

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Multiphysics simulation of plasma channel formation during micro-electrical discharge machining

AIP Advances ◽

10.1063/5.0028665 ◽

2021 ◽

Vol 11 (2) ◽

pp. 025138

Author(s):

Sohaib Raza ◽

Chandrakant Kumar Nirala

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Plasma Channel ◽

Channel Formation ◽

Multiphysics Simulation ◽

Micro Electrical Discharge Machining

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

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/0954408920984402 ◽

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.

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