Laser Induced Plasma Micro-Machining

2010 ◽  
Author(s):  
Kumar Pallav ◽  
Kornel F. Ehmann
Keyword(s):  
Tool Wear ◽  
Material Removal ◽  
Machining Process ◽  
Micro Edm ◽  
Micro Machining ◽  
Workpiece Surface ◽  
Laser Induced Plasma ◽  
New Process ◽  
Explosive Expansion ◽  
Edm Process

A new micro-machining process that is motivated by the need to overcome the various limitations associated with the micro-EDM (μ-EDM) process is introduced. The limitations in μ-EDM are primarily due to the requirement of a conductive electrode and workpiece, tool wear, and complex wear compensation strategies. The new process, termed “laser-induced plasma micro-machining” uses a laser beam to generate plasma in a dielectric near the workpiece surface whose explosive expansion results in material removal by mechanisms similar to those that occur in μ-EDM.

A REVIEW ON VIBRATION-ASSISTED EDM, MICRO-EDM AND WEDM

2019 ◽  
Vol 26 (05) ◽  
pp. 1830008 ◽  
Author(s):  
K. P. MAITY ◽  
M. CHOUBEY
Keyword(s):  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Electrode Wear ◽  
Micro Edm ◽  
Vibration Parameters ◽  
Unconventional Machining ◽  
Edm Process

Electrical discharge machining (EDM) is an unconventional machining process used for machining of hard-to-cut materials. Both EDM and micro-EDM processes are extensively used for producing dies and molds, complex cavities, and 3D structures. In recent years, researchers have intensively focused on improving the performance of both micro-EDM and EDM processes. This paper reviews the research work carried out by the researchers on vibration-assisted EDM, micro-EDM, and wire EDM. The consolidated review of this research work enables better understanding of the vibration-assisted EDM process. This study also discusses the influence of vibration parameters such as vibration frequency and amplitude on the material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR). The important issues and research gaps in the respective area of research are also presented in this paper.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

A Comparison of Generator Mode on the Performance of Finish EDM of AISI P20 Tool Steel

2004 ◽  
Author(s):  
Fred L. Amorim
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Technical Information ◽  
Relaxation Mode ◽  
Workpiece Surface ◽  
Aisi P20 ◽  
Edm Process ◽  
Aisi P20 Steel

The AISI P20 steel is applied by the tooling industry as material for injection molding tools. It is known that the EDM process parameters technology installed at the majority of CNC EDM machines do not cover some of the necessities of the tooling industry. So, the customers are required to develop their own process parameters. In order to provide useful technical information to the industry an experimental investigation on the EDM of the AISI P20 tool steel under finish machining has been carried out. The material removal rate Vw, volumetric relative wear v and workpiece surface texture Ra, which are representative of EDM performance aspects, were analyzed against the variation of some of the most important EDM electrical variables using copper tool electrodes under positive and negative polarity. The EDM machine generator was also programmed to actuate under isoenergetic mode and relaxation mode. The results are discussed and some appropriate parameters for EDM of AISI P20 are suggested.

Multi-Material Capability of Laser Induced Plasma Micromachining

2014 ◽  
Author(s):  
Ishan Saxena ◽  
Kornel Ehmann
Keyword(s):  
Laser Ablation ◽  
Metal Cutting ◽  
Medical Engineering ◽  
Machining Process ◽  
Micro Machining ◽  
Promising Alternative ◽  
Laser Induced Plasma ◽  
Direct Laser ◽  
Micro Features ◽  
Machining Characteristics

Presently surface micro-texturing has found many promising applications in the fields of tribology, bio-medical engineering, metal cutting, and other functional or topographical surfaces. Most of these applications are material-specific, which necessitates the need for a texturing and machining process that surpasses the limitations posed by a certain class of materials that are difficult to process by laser ablation, owing to their optical or other surface or bulk characteristics. Laser Induced Plasma Micromachining (LIPMM) has emerged as a promising alternative to direct laser ablation for micro-machining and micro-texturing, which offers superior machining characteristics while preserving the resolution, accuracy and tool-less nature of laser ablation. This study is aimed at understanding the capability of LIPMM process to address some of the issues faced by pulsed laser ablation in material processing. This paper experimentally demonstrates machining of optically transmissive, reflective and rough surface materials using LIPMM. Apart from this, the study includes machining of conventional metals (Nickel and Titanium) and polymer (Polyimide), to demonstrate higher obtainable depth and reduced heat affected distortion around micro-features machined by LIPMM, as compared to laser ablation.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

On the Development of an Experimental Testing Platform for the Vortex Machining Process

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Stephen C. Howard ◽  
Jacob W. Chesna ◽  
Stuart T. Smith ◽  
Brigid A. Mullany
Keyword(s):  
Material Removal ◽  
Closed Loop ◽  
Experimental Testing ◽  
Machining Process ◽  
Gaussian Shape ◽  
Workpiece Surface ◽  
Loop Control ◽  
Height Control ◽  
Stability Issues ◽  
Process Controls

The development of an experimental platform for studying Vortex Machining is presented. This process uses oscillating probes to generate localized vortices in polishing slurry in a region near to a workpiece surface. These vortices create material removal footprints having lateral dimensions typically measuring tens of micrometers. From studies of the process variables and subsequent machining footprints a number of process controls have been implemented and are discussed herein. These include a localized metrology frame to control specimen to probe position, coarse-fine translation axes for submicrometer motion control, closed-loop control of probe oscillation, and a slurry height control system. To illustrate the fidelity of these additional controls, the evolution from early machining footprints to the recent production of footprint arrays are presented. While process stability issues remain, machining footprints of near Gaussian shape having dimensions of 10–20 μm diameter and 40 nm depth after machining for 30 min can be reproduced.

Enhancing the Surface Quality by Iso Pulse Generator in EDM Process

2012 ◽  
Vol 622-623 ◽  
pp. 380-384 ◽  
Author(s):  
T. Muthuramalingam ◽  
B. Mohan
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Discharge Energy ◽  
Crater Volume ◽  
Machining Characteristics ◽  
Edm Process

In automobile and aeronautical industries, complex moulds and dies is produced by Electrical Discharge Machining process. The surface finish is determined by the crater volume in EDM process. The amount of crater volume is influenced by the amount and distribution of discharge energy. The discharge energy is directly proportional to the average discharge current. This amount of current is determined by the duration of discharging effect. This study deals about evaluating the performance of iso current pulse generator on machining characteristics in EDM. Due to its ability of reducing stochastic nature in EDM process, iso pulse generator could produce better surface finish than conventional transistor pulse train generator with higher material removal rate.

Research of PZT Excited Discharge Channel Compression Micro-EDM Techniques

2013 ◽  
Vol 645 ◽  
pp. 363-366
Author(s):  
Lian Ming Du ◽  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Ya Zhang
Keyword(s):  
Discharge Channel ◽  
Removal Rate ◽  
New Technology ◽  
Machining Process ◽  
Micro Edm ◽  
System Composition ◽  
The Stability ◽  
Discharge Gap ◽  
Edm Process ◽  
Sync Pulse

In micro-EDM, the debris generated in machining process is difficult to be moved from the discharging gap, the discharge state is instability, and the material removal rate is low. A new method of PZT incentive synchronous compression discharge channel micro-EDM is presented based on the inverse piezoelectric effect of PZT piezoelectric ceramics, using a spark discharge and PZT sync pulse power. In this paper, the system composition and machining principles are described in detail, and its machining mechanism is analyzed in terms of the experiments. By the experiments, it is certificated that on the process of PZT sync compressing discharge channel machining, the state of discharge gap, the machining efficiency and quality can be improved, the throw out of debris makes easier, and then the stability of micro-EDM process is raised, which indicated that this new technology has wide application prospect in the field of micro manufacturing.

scholarly journals Machinability Of Shape Memory Alloy Using Electro Spark Erosion Process 

2021 ◽  
Author(s):  
Adam Khan M ◽  
Winowlin Jappes J T ◽  
Samuel Ratna Kumar P S ◽  
Mashinini P M
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Shape Memory ◽  
Applied Voltage ◽  
Material Removal ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Pulse On Time ◽  
The Impact

Abstract In this research work, the nickel – titanium based shape memory alloys are machined using electro spark machining process. The influence of the input process for electro spark production is studied in detail. From the analysis, the tool wear rate (TWR), surface roughness, and material removal rate (MRR) are investigated. The intensity of the electro spark produced at minimum pulse on-time 10 µs and maximum applied voltage (60 V). Variation in MRR is wide for a minimum pulse on time with low applied voltage. The surface roughness of the machined surface is also directly influenced by the in – efficient spark produced. The copper electrode with increase pulse duration the alloy behaves like a strong conductor to transmit electrical energy between the electrode and work material. The contribution of pulse on-time is maximum for material removal and tool wear rate. However, the surface finish depends on the applied voltage of the process designed. The impact on machined surfaces, micro-cracks, electro-discharge carter's, and recast material due to electrical discharge were assessed using a scanning electron microscope and energy-dispersive X-ray spectroscopy (EDX) analysis. The experimental value shows that material removal depends on the pulse on process timings and applied voltage. Thus, by using mathematical analysis the influence of (electric discharge machining) EDM process parameters was evaluated.

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