Copper–tungsten electrode wear process and carbon layer characterization in electrical discharge machining

2015 ◽  
Vol 85 (5-8) ◽  
pp. 1759-1768 ◽  
Author(s):  
Lihua He ◽  
Jianwu Yu ◽  
Wen Duan ◽  
Zhikang Liu ◽  
Shaohui Yin ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Carbon Layer ◽  
Electrode Wear ◽  
Tungsten Electrode ◽  
Wear Process

An Experimental Study on Electrical Discharge Machining of Copper Alloy Grade HR750

2013 ◽  
Vol 816-817 ◽  
pp. 75-79 ◽  
Author(s):  
Apiwat Muttamara ◽  
Nitipud Treeranurat
Keyword(s):  
Copper Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Recast Layer ◽  
Machining Process ◽  
Electrode Wear ◽  
Tungsten Electrode ◽  
Workpiece Material

Electrical discharge machining process (EDM) is a process for removing material by the thermal of electrical discharge. EDM process melts and evaporates workpiece material. Some of the melted and all of the evaporated material is then quenched and flushed away by dielectric liquid and the remaining melt recast on the finished surface. The recast layer is called as white layer. Beneath the recast layer, a heat affected zone is formed. The quality of an EDM product is usually evaluated in terms of its surface integrity, which is characterized by existence of surface cracks and residual stresses. The machinability of EDM in terms of the material removal rate and electrode wear ratio was evaluated in this paper. The machining tests were carried out on a copper alloy grade HR750 with a copper tungsten electrode. The workpiece surfaces are analyzed by optical microscope and XRD technique. The formation of crack is not found.

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.

Electrode Wear Process in Electrical Discharge Machinings

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 165-168 ◽  
Author(s):  
Naotake Mohri ◽  
Masayuki Suzuki ◽  
Masanori Furuya ◽  
Nagao Saito ◽  
Akira Kobayashi
Keyword(s):  
Electrical Discharge ◽  
Electrode Wear ◽  
Wear Process

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.

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.

Synthesis of Electrical Discharge Metal Matrix Composite Coating Through Compacted Semi-Sintered Electrode and Its Tribological Studies

2018 ◽  
Author(s):  
Arun Ilangovan ◽  
C. Yuvaraj ◽  
P. Selvarani ◽  
J. S. Senthilkumaar ◽  
S. Thamizhmanii
Keyword(s):  
Metal Matrix ◽  
Electrical Discharge ◽  
Compaction Pressure ◽  
Electrical Discharge Machine ◽  
Carbon Layer ◽  
Substrate Material ◽  
Matrix Composition ◽  
Mixed Composition ◽  
Tungsten Electrode ◽  
Material Migration

Electric Discharge Coating an alternate process for surface modification/alloying/coating to improve the mechanical and metallurgical properties of the materials using conventional Electrical Discharge Machine. The compaction pressure of semi-sintered nickel and tungsten electrode influences the material migration together with substrate material and pyrolysis carbon results in metal matrix composition coating. In depended of pressure spark gap are stable increases the deposition of alloying materials lessens the formation carbon layer, cracks, voids, blowhole over the surface and made the layer to be metallurgical mixed composition surface that reduces the brittleness. This makes the layer four times higher in hardness value than the substrate material to 1100HV0.5 and reduction in specific wear to 0.082x10-5mm3/Nm depends on the inclusion of alloying material with carbon percentage consequences in self-lubricant properties that varies the wear rate. Surfaces topography obtained during alloying, material migration, mechanism is characterized through Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray spectroscopy (EDX)and wear through pin-on-disc tribometer

scholarly journals Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1647
Author(s):  
Yue-Peng Zeng ◽  
Chiang-Lung Lin ◽  
Hong-Mei Dai ◽  
Yan-Cherng Lin ◽  
Jung-Chou Hung
Keyword(s):  
Process Parameters ◽  
Performance Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Technique ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relative Closeness ◽  
Machining Parameter

The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

Effect of Wire Electrode Materials on Performance Characteristics for Wire Electrical Discharge Machining of Metal Matrix Composite Material

2020 ◽  
Author(s):  
Gurupavan Hurugalavadi Ramu ◽  
Holalu Venkatadas Ravindra ◽  
Devegowda Tadagavadi Muddegowda
Keyword(s):  
Silicon Carbide ◽  
Composite Materials ◽  
Surface Finish ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Electrode Wear ◽  
Wire Electrical Discharge Machining ◽  
Brass Wire

Abstract Composite materials are the advanced materials which are widely used in manufacturing industries. The most commonly used composite materials are metal matrix composites. Due to the presence of abrasive reinforcing particles, traditional machining of these causes severe tool wear and hence reduces the life of cutting tool. Wire electrical discharge machining (WEDM) is quite successful for machining of metal matrix composites. Wire Electrical Discharge machining is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. One of the main research fields in WEDM is related to the improvement of the process productivity by avoiding wire breakage. Wire electrodes used in WEDM are the core of the system. In this study the effect of different wire electrode materials on electrode wear and surface finish for wire electrical discharge machining of metal matrix composite material were investigated. The experiments were conducted under the following process parameters viz., pulse-on time, pulse-off time, wire feed speed and current. For the experiment the aluminium 6061 alloy with 0%, 5%, and 10% of silicon carbide (SiC) reinforcement material was used. To conduct the experiment CNC wire EDM machine with two different wires viz., molybdenum and brass wire was used. Experimental results indicate that for better surface finish of Al6061 alloy, the brass wire is more suitable. The use of brass wire as electrode material leads to significant reduction in electrode wear in machining of Al-5%SiC and Al-10%SiC composite materials compare to molybdenum wire. Increasing percentage of silicon carbide in aluminium 6061 alloy increases the variation in surface finish and electrode wear. Wire wear rate of both brass and molybdenum wire is increased with increase in percentage of silicon carbide.

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