Performance of electrical energy based unconventional machining processes – Review

The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.

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Hybrid machining processes. Definitions, generation rules and real industrial importance

Mechanik ◽

10.17814/mechanik.2018.5-6.50 ◽

2018 ◽

Vol 91 (5-6) ◽

pp. 338-342

Author(s):

Wit Grzesik

Keyword(s):

Classification Systems ◽

Energy Sources ◽

Future Trends ◽

Synergic Effect ◽

Machining Processes ◽

Hybrid Machining ◽

Hybrid Processes ◽

Potential Applications ◽

Advanced Machining ◽

Unconventional Machining

Some important trends in the development of advanced machining processes with potential applications in Production/Manufacturing 4.0 are presented. In general, both conventional and unconventional machining processes are characterized in terms of potential technological possibilities related to their hybridization allowing the performance of more productive and effective machining processes. This is due to the fact that hybrid processes considerably enhance the advantages of individual processes and minimize potential disadvantages in individual processes. Possible classification systems of hybrid processes including the CIRP terminology are overviewed and some representative examples are provided. In particular, the hybrid machining processes based on the simultaneous and controlled interaction of process mechanisms and/or energy sources leading to the synergic effect (1 + 1 = 3) on the process performance are taken into account. Some conclusions and future trends in the implementation of hybrid processes are outlined.

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Electrical arc machining: Process capabilities and current research trends

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406219846151 ◽

2019 ◽

Vol 233 (15) ◽

pp. 5190-5200 ◽

Cited By ~ 4

Author(s):

Pankaj Kumar Shrivastava ◽

Shrihar Pandey ◽

Shivam Dangi

Keyword(s):

Removal Rate ◽

Machining Process ◽

Advanced Materials ◽

Future Research ◽

Machining Processes ◽

Workpiece Material ◽

Electrical Arc ◽

Control Factors ◽

Conductive Ceramics ◽

Unconventional Machining

Electrical arc machining is the thermal energy-based unconventional machining process, which utilizes energy of arc to melt and vaporize workpiece material. Electrical arc machining has the capability to machine advanced materials such as metal matrix composites, superalloys, and conductive ceramics effectively. The process is considered to be efficient than most of the other unconventional machining processes in terms of the material removal rate. But it has got limitations because it results in a very poor surface finish. Tool wear rate, recast layer formation, surface and subsurface cracks, and geometrical inaccuracy are other limitations up to a certain extent. In this paper, the comprehensive review of research carried out so for in the area of electrical arc machining has been presented. The paper discusses the detailed experimental and theoretical studies done on electrical arc machining to elucidate the effects of various input control factors on different quality characteristics. The paper also contains modeling and optimization studies done so far in electrical arc machining and finally discusses the future research possibilities in the area.

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