A novel approach to plasma channel radius determination and numerical modeling of electrical discharge machining process

2020 ◽  
Vol 42 (4) ◽  
Author(s):  
Ahad Gholipoor ◽  
Mohammad Reza Shabgard ◽  
Mousa Mohammadpourfard
Keyword(s):  
Numerical Modeling ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Plasma Channel ◽  
Machining Process ◽  
Channel Radius ◽  
Novel Approach

An Experimental Study of the Phenomenon of Surface Alloying by EDM Process Using Inconel Tool Electrode

2013 ◽  
Author(s):  
Sanjeev Kumar
Keyword(s):  
Experimental Study ◽  
Surface Properties ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Plasma Channel ◽  
Machining Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Surface Alloying ◽  
Machining Conditions

Electrical Discharge Machining (EDM) has emerged as a very important machining process due to its numerous advantages. It is extensively used by the die and toolmaking industry for the accurate machining of complex internal profiles. Although EDM is essentially a material removal process, it has been used successfully for improving the surface properties of the work materials after machining. As the dissolution of the electrode takes place during the process, some of its constituents may alloy with the machined surface under appropriate machining conditions. Additive powders in the dielectric medium may form part of the plasma channel in the molten state and produce similar alloying effect. The breakdown of the hydrocarbon dielectric under intense heat of the spark contributes carbon to the plasma channel. Sudden heating and quenching in the spark region also alters the surface properties. This paper reports the results of an experimental study into electrical discharge machining of H13 hot die steel with Inconel (an alloy of chromium, nickel and iron) tool electrode under machining conditions favouring high electrode wear. The results show improvement in micro-hardness after machining by as much as 88%. Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) analysis of the machined surfaces show transfer of chromium and nickel from the tool electrode. Both these elements form intermetallic compounds as well as solid solution with iron and strengthen it. It was found that percentage of chromium increased from 5.39% to 6.52% and that of nickel increased from 0.19% to 4.87%. The favourable machining conditions for surface alloying were found to be low value of peak current, shorter pulse on-time, longer pulse off-time and negative polarity of the tool electrode.

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.

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.

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