A Computational Model to Study Film Formation and Debris Flushing Phenomena in Spray-Electric Discharge Machining

2016 ◽  
Vol 4 (3) ◽  
Author(s):  
Arvind Pattabhiraman ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Film Thickness ◽  
Computational Model ◽  
Electric Discharge ◽  
Dielectric Film ◽  
Film Formation ◽  
Electric Discharge Machining ◽  
Spray Formation ◽  
Spray System ◽  
Debris Particles ◽  
Interelectrode Gap

A computational model to investigate the flushing of electric discharge machining (EDM) debris from the interelectrode gap during the spray-EDM process is developed. Spray-EDM differs from conventional EDM in that an atomized dielectric spray is used to generate a thin film that penetrates the interelectrode gap. The debris flushing in spray-EDM is investigated by developing models for three processes, viz., dielectric spray formation, film formation, and debris flushing. The range of spray system parameters including gas pressure and impingement angle that ensure formation of dielectric film on the surface is identified followed by the determination of dielectric film thickness and velocity. The debris flushing in conventional EDM with stationary dielectric and spray-EDM processes is then compared. It is observed that the dielectric film thickness and velocity play a significant role in removing the debris particles from the machining region. The model is used to determine the spray conditions that result in enhanced debris flushing with spray-EDM.

Atomized Dielectric Spray-Based Electric Discharge Machining for Sustainable Manufacturing

2015 ◽  
Vol 3 (4) ◽  
Author(s):  
Arvind Pattabhiraman ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Dielectric Medium ◽  
Discharge Zone ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Dry Edm ◽  
Debris Particles ◽  
Interelectrode Gap

A novel method of using atomized dielectric spray in micro-electric discharge machining (EDM) (spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the interelectrode gap and acts as a single phase dielectric medium between the electrodes and also effectively removes the debris particles from the discharge zone. Single-discharge micro-EDM experiments are performed using three different dielectric supply methods, viz., conventional wet-EDM (electrodes submerged in dielectric medium), dry-EDM, and spray-EDM in order to compare the processes based on material removal, tool electrode wear, and flushing of debris from the interelectrode gap across a range of discharge energies. It is observed that spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study. The tool electrode wear using atomized dielectric is significantly better than dry-EDM and comparable to that observed in wet-EDM. The percentage of debris particles deposited within a distance of 100 μm from the center of EDM crater is also significantly reduced using the spray-EDM technique.

scholarly journals Modeling of Interelectrode Gap in Electric Discharge Machining and Minimum Variance Self-Tuning Control of Interelectrode Gap

2020 ◽  
Vol 2020 ◽  
pp. 1-20
Author(s):  
Bin Xin ◽  
Ming Gao ◽  
Shujuan Li ◽  
Bin Feng
Keyword(s):  
Electric Discharge ◽  
Removal Rate ◽  
Short Circuit ◽  
Minimum Variance ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
Precise Control ◽  
Interelectrode Gap ◽  
Machining System ◽  
P Type

In the electric discharge machining system, the determination of the gap between the anode and the cathode is a difficult point of this kind of machining approach. An accurate mathematical model of interelectrode gap is obtained, and the precise control of the gap is achieved on this basis. In this paper, based on the example of discharge machining of P-type single crystal Si, the theoretical analysis proved that the discharge channel can be equivalent to pure resistance, and the physical model of the interelectrode gap and voltage and current was established. The order and parameters of the EDM system model were determined by adopting the system identification theory. We designed the minimum variance self-correcting controller to accurately control the interelectrode gap in combination with the actual machining process. Experimental results show that the interelectrode gap model can correctly reflect the interelectrode gap in the actual machining process; the minimum variance self-correcting controller eliminates the short circuit phenomenon during processing and can stably track different desired gaps; the material removal rate and the surface roughness decrease with the increase of the interelectrode gap.

Study on different types of electric discharge Machining Methods: A review

2021 ◽  
Author(s):  
Sanjay Sundriyal ◽  
Mohammad Zaheen Khan ◽  
Bharat Raj Bundel ◽  
Iqbal Ahmed Khan
Keyword(s):  
Electric Discharge ◽  
Electric Discharge Machining ◽  
Different Types

scholarly journals The Effect of Film Thickness and Content on Film Formation from PS/ Nanocomposites Prepared by Dip-Coating Method

2012 ◽  
Vol 2012 ◽  
pp. 1-17 ◽  
Author(s):  
M. Selin Sunay ◽  
Onder Pekcan ◽  
Saziye Ugur
Keyword(s):  
Film Thickness ◽  
Elevated Temperatures ◽  
Film Formation ◽  
Fluorescence Emission ◽  
Dip Coating ◽  
Atomic Force ◽  
Annealing Step ◽  
Coating Method ◽  
Fluorescence Emission Intensity ◽  
Dip Coating Method

Steady-state fluorescence (SSF) technique in conjunction with UV-visible (UVV) technique and atomic force microscope (AFM) was used for studying film formation from TiO2covered nanosized polystyrene (PS) latex particles (320 nm). The effects of film thickness and TiO2content on the film formation and structure properties of PS/TiO2composites were studied. For this purpose, two different sets of PS films with thicknesses of 5 and 20 μm were prepared from pyrene-(P-) labeled PS particles and covered with various layers of TiO2using dip-coating method. These films were then annealed at elevated temperatures above glass transition temperature () of PS in the range of 100–280°C. Fluorescence emission intensity, from P and transmitted light intensity, were measured after each annealing step to monitor the stages of film formation. The results showed that film formation from PS latexes occurs on the top surface of PS/TiO2composites and thus developed independent of TiO2content for both film sets. But the surface morphology of the films was found to vary with both TiO2content and film thickness. After removal of PS, thin films provide a quite ordered porous structure while thick films showed nonporous structure.

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