Micro-Machining of Glass Using Electrochemical Discharge Assisted Cutting

2016 ◽  
Author(s):  
Baoyang Jiang ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Geometric Accuracy ◽  
Machine Material ◽  
Hybrid Machining ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Hybrid Machining Process

Glass is a hard-to-machine material with vast industrial application. Electrochemical discharge machining (ECDM) is a non-traditional machining technology that has shown potential for effective glass machining. However, ECDM has not been widely used in industry despite being studied for over a decade. Major challenges of ECDM include limited machinable depth and low material removal rate. In this paper, an innovative hybrid machining process combining ECDM and traditional cutting is presented, namely electrochemical discharge assisted cutting. The material removal rate of the hybrid ECDM process is significantly higher than conventional processes. Experimental results are presented to prove the feasibility and capability of the process. Discussion concentrates on the improvement of geometric accuracy and surface integrity through experimentation.

Experimental Investigation of Drilling Incorporated Electrochemical Discharge Machining

2014 ◽  
Author(s):  
Baoyang Jiang ◽  
Shuhuai Lan ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Drilling Process ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Drilling

Electrochemical discharge machining (ECDM) is a non-conventional micromachining technology, and is highlighted for non-conductive brittle materials. However, the outcomes of ECDM have many restrictions in application due to limitations on efficiency, accuracy, and machining quality. In this paper, a drilling incorporated ECDM process is presented and analyzed to enhance material removal rate in ECDM drilling process. Incorporating micro-drilling into ECDM significantly increases the rate of material removal, especially in deep hole drilling. As fundamentals of the machining process, material removal mechanisms have been investigated to account for the increment in material removal rate by incorporating micro-drilling. Vibration of tool electrode, induced by a piezo-actuator, was introduced to further enhance material removal rate. Quantitative studies were conducted to determine the appropriate process parameters of drilling incorporated ECDM with tool vibration.

Optimization of Process Parameters in Micro-Electrochemical Discharge Machining by Using Grey Relational Analysis

2020 ◽  
Vol 978 ◽  
pp. 121-132
Author(s):  
Nitesh Kumar ◽  
Harish Bishwakarma ◽  
Prasenjit Sharma ◽  
Purshottam Kumar Singh ◽  
Alok Kumar Das
Keyword(s):  
Electrolyte Concentration ◽  
Removal Rate ◽  
Machining Process ◽  
Duty Factor ◽  
Work Piece ◽  
Machining Parameters ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Hybrid Machining Process ◽  
Micro Hole

Micro-electrochemical discharge machining is hybrid machining process which is based on combined principle of electro discharge machining and electro chemical machining. It is suitable for machining of both conductive as well as non-conductive materials. In this study a micro hole drilled on Ti-6Al-4V as work piece by varying machining parameters like electrolyte concentration, voltage and duty factor at three different levels. Orthogonal array L9 considered for design and performing experiments. The Grey relation analysis (GRA) was performed to optimize the output parameters i.e. material removal rate (MRR) and hole tapper angle (HTA). The result reveals that voltage was the most significant factor for both MRR and HTA followed by electrolyte concentration and duty factor. The maximum MRR and minimum taper angle are 1.50 mg/min and 0.98 ° obtained respectively. The GRA show optimal machining parameters at electrolyte concentration 3M, voltage 40 V and duty factor 25% respectively.

Influence of Dielectric Jet Flushing during Electro Discharge Diamond Surface Grinding Process

2013 ◽  
Vol 652-654 ◽  
pp. 2187-2190
Author(s):  
Gopal Agarwal ◽  
Manoj Modi
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Hybrid Machining Process

The influence of dielectric jet flushing during Electro Discharge Diamond Surface Grinding (EDDSG) on Ti-6A-4V has been reported in this paper. The metal bonded diamond grinding wheel is used as electrode in Electro Discharge Diamond Surface Grinding process. In this process mechanical grinding is coupled with electrical spark of electrical discharge machine to take up the advantages associated with hybrid machining process. The important input parameters in this investigation were “duty factor”, “wheel speed (rpm)”, “magnitude of current (ampere)” and its “duration (Ton, micro-second)”. The effects of these parameters on outcomes i.e. material removal rate (MRR) and surface roughness (Ra) are measured. The noticeable enhancements in material removal rate and surface finish have been seen during EDDSG of Ti-6Al-4V with effective jet flushing. The performance of EDDSG with jet flushing and without jet flushing has been compared.

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.

Schruppfräsbearbeitung von Verdichterscheiben/Milling of compressor disk - Identification of a cutting material and coating combination for high process reliability

2017 ◽  
Vol 107 (09) ◽  
pp. 674-680
Author(s):  
E. Prof. Abele ◽  
C. Hasenfratz ◽  
C. Praetzas ◽  
G. M. Schüler ◽  
C. Stark ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Manufacturing Technology ◽  
Machining Process ◽  
Complex Task ◽  
Eine Hohe ◽  
Process Reliability ◽  
Rough Milling ◽  
Compressor Disk

Die Herstellung von Verdichterscheiben stellt hohe Ansprüche an die Fertigungstechnik. Neue, schwer zu zerspanende Materialien und Integralkonstruktionen erzeugen eine hohe Komplexität bei der Ausführung. Das Projekt „SchwerSpan“ stellt sich dieser Herausforderung und entwickelt einen Prozess zur Schruppfräsbearbeitung von Verdichterscheiben. Ziel des Projekts ist eine Reduktion der Werkzeugkosten bei erhöhtem Zeitspanvolumen.   The production of compressor disks places high demands on the manufacturing technology. A very complex task is created by new difficult-to-cut materials and integral components. The project “SchwerSpan” is taking on this task by developing a machining process for rough milling in the production of compressor disks. The aim of the process is to reduce the tool costs by increasing material removal rate.

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

2018 ◽  
Vol 233 (6) ◽  
pp. 1896-1909 ◽  
Author(s):  
VG Ladeesh ◽  
R Manu
Keyword(s):  
Material Removal Rate ◽  
Borosilicate Glass ◽  
Chemical Etching ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Hybrid Technique ◽  
Machined Surface ◽  
Influence Of Process Parameters ◽  
Electrochemical Discharge

The electrically non-conductive materials like glass, ceramics, quartz, etc. are of great interest for many applications in modern industries. Machining them with high quality and at a faster rate is a challenging task. In this study, a novel technique called grinding aided electrochemical discharge drilling (G-ECDD) is demonstrated which uses a hollow diamond core drill as the tool for performing electrochemical discharge machining of borosilicate glass. The new hybrid technique enhances the material removal rate and machining accuracy to several folds by combining the thermal melting action of discharges and grinding action of the abrasive tool. This paper presents the experimental investigation on the material removal rate during G-ECDD of glass while using different electrolytes. An attempt has been made to explore the influence of electrolyte temperature on G-ECDD performance by maintaining the electrolyte at different temperatures. Experiments were conducted using three different electrolytes which include NaOH, KOH, and the mixture of both. The results obtained from this study revealed that an increase in temperature will favor chemical etching as well as electrochemical reaction rate. Also, it was observed that heating the electrolyte leads to an increase in the bubble density and enhances the ion mobility. This causes the formation of gas film at a faster rate and thereby improving the discharge activity. Thus, machining will be done at a faster rate. Better results are obtained while using a mixture of NaOH and KOH. From the microscopic images of the machined surface, it was observed that material removal mechanism in G-ECDD is a combination of grinding action, electrochemical discharges, and chemical etching. Response surface methodology was adopted for studying the influence of process parameters on the performance of G-ECDD. The new technique of grinding aided electrochemical discharge drilling proved its potential to machine borosilicate glass and simultaneously offers good material removal rate, repeatability, and accuracy.

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