Reducing electrode wear ratio using cryogenic cooling during electrical discharge machining

2009 ◽  
Vol 45 (11-12) ◽  
pp. 1146-1151 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cryogenic Cooling ◽  
Electrode Wear ◽  
Wear Ratio

Reducing Electrode Wear Using Cryogenic Cooling during Electrical Discharge Machining

2009 ◽  
Vol 83-86 ◽  
pp. 672-679 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Electrode Material ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cryogenic Cooling ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electrode Tool ◽  
Pulse On Time

In electrical discharge machining (EDM), material is removed by a series of electrical discharge between the electrode (tool) and the workpiece that develops a temperature of about 8,0000C to 12,0000C. Due to high temperature of the sparks, work material is melted and vapourized, at the same time the electrode material is also eroded by melting and vapourization. Electrodes wear (EW) process is quite similar to the material removal mechanism as the electrode and the workpiece are considered as a set of electrode in EDM. In the present study effort has been made to reduce EW by cooling, using liquid nitrogen during the EDM of titanium alloy. Investigation on the effect of cooling on electrode wear (EW), material removal rate (MRR) and surface roughness (Ra) of the workpiece was carried out. Current (I), pulse on-time (ton), pause off-time (toff) and voltage (v) were considered as the machining parameters. Design of experiment (DOE) was used to design the experimental works. Cooling of electrode by this technique reduced the melting and vapourization of electrode material and enhances electrode life. It was possible to reduce EW up to 27% by applying this technique while MRR and Ra were improved by 18% and 8% respectively.

Recent Patents on Micro-EDM Milling

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.

Deep Hole of AISI P20 Mold Steel Material by Electrical Discharge Machining

2014 ◽  
Vol 590 ◽  
pp. 244-248
Author(s):  
Jamkamon Kamonpong ◽  
Pichai Janmanee
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Side Surface ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Steel Material ◽  
Suitable Parameter ◽  
Aisi P20 ◽  
Off Time

This research aimed to study the machining efficiency of AISI P20 steel by Electrical Discharge Machining (EDM) using rod copper electrode to machining material by 50 mm depth of machining was mainly assessed from Materials Removal Rate (MRR) and Electrode Wear Ratio (EWR). From the experiment designed to use Taguchi technique of data analysis and suitable parameter prediction, the highest MRR was at on-time of 150 μs, off-time of 2 μs and electric current level was at 15 A or 0.25 A/mm2. Predicted value was at 19.2395 mm3/min which was equal to real experiment, showing Materials Removal Rate of 19.647 mm3/min (with error of 2.12 percent) .Moreover, it was found that gap would increase with the size of electrode and depth of machining caused by movement of particles removed from side surface of electrode, which cause micro sparks at the side of the material workpiece.

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.

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

2020 ◽  
Vol 235 (1-2) ◽  
pp. 125-133
Author(s):  
Omer Eyercioglu ◽  
Kursad Gov
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Magnesium Content ◽  
Machining Process ◽  
Electrode Wear ◽  
Ti Alloy ◽  
Ti Alloys ◽  
Mg Content

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

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