High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

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.

Multi-Objective Optimization of PMEDM Process of 90CrSi Alloy Steel for Minimum Electrode Wear Rate and Maximum Material Removal Rate with Silicon Carbide Powder

2021 ◽  
Vol 1018 ◽  
pp. 51-58
Author(s):  
Tran Thi Hong ◽  
Nguyen Van Cuong ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Silicon Carbide ◽  
Alloy Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Carbide Powder ◽  
Electrode Wear ◽  
Silicon Carbide Powder

This study aims to minimize electrode wear (EW) and maximize material removal rate (MRR) in powder mixed electrical discharge machining (PMEDM) process of 9CrSi alloy steel with silicon carbide powder. To achieve these objectives, Taguchi method and Grey Relational Analysis (GRA) are applied to optimize one two-level and four three-level PMEDM process parameters, including Ton, Toff, CP, IP and SV in eighteen experiments based on an orthogonal array L18 (21 and 43). Results have provided a set of optimal PMEDM process parameters in which Ton has the strongest effect on SW and MRR while that of CP is insignificant. The obtained minimum EW and maximum MRR have been verified and proven by a PMEDM experiment using optimal process parameters. The proposed method can be further applied to optimize other PMEDM process parameters for different objectives.

Influence of Workpiece Shape on MRR and EWR in EDM of Steel

2014 ◽  
Vol 903 ◽  
pp. 51-55 ◽  
Author(s):  
Alexis Mouangue Nanimina ◽  
Ahmad Majdi Abdul Rani ◽  
Mohd Amri Lajis ◽  
Turnad Lenggo Ginta ◽  
T.V.V.L.N. Rao
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Electrode Wear ◽  
Wear Ratio ◽  
Flat Shape ◽  
Dielectric Flushing ◽  
Edm Process

Shape of workpiece, electrode orientation and flushing system play important role in electrical discharge machining (EDM) process. Low material removal rate and relatively high electrode wear ratio are some of the disadvantages of EDM process. This can be due to the flushing modes. Workpiece shape has a significant effect in effectiveness of dielectric flushing flow and orientation during EDM process. This research work is conducted to analyze the influence of various workpiece shapes. Square cavity, L shape, flat shape and U shape were machined with same cross-section electrode material. Test parameters are material removal rate (MRR) and electrode wear ratio (EWR). Experiment results show slight difference in MRR and EWR values for different shapes. U shape presents the highest MRR and the lowest EWR occurs in flat shape compared to cavity and L shapes. It can be concluded that flat and U shapes result in good EDM machining quality due to good dielectric flow and flushing conditions in the area of EDM machining.

Effect of Thickening Agent on Water-Based Working Fluid for EDM

2009 ◽  
Vol 407-408 ◽  
pp. 644-648
Author(s):  
Ren Jie Ji ◽  
Yong Hong Liu ◽  
Li Li Yu ◽  
Ji Ming Chen ◽  
Rong Shen ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Working Fluid ◽  
Electrode Wear ◽  
Thickening Agent ◽  
Water Based ◽  
Thickening Agents ◽  
Discharge Gap

Different thickening agents are added into the prepared water-based working fluid for electrical discharge machining (EDM), and the influence on the process performance is investigated in this paper. The experimental results demonstrate that the proper addition of polyvinyl alcohol (PVA) and coconut diethanol amide (CDEA) can increase the material removal rate of EDM, advance the electrical conductivity of the working fluid and enlarge the discharge gap, but has a little influence on the relative electrode wear ratio. Moreover, the material removal rate can increase 1.1 times and 1.3 times with proper addition of PVA and CDEA respectively in comparison with no thickening agent, and the addition of CDEA promotes better EDM performance

Experimental Research on Technology of Ultrasonic Vibration Aided Electrical Discharge Machining (UEDM) in Gas

2006 ◽  
Vol 315-316 ◽  
pp. 81-84 ◽  
Author(s):  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Q.B. Zhang ◽  
Shu Peng Su
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Environment Pollution ◽  
Dielectric Fluids

Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is an electrical discharge machining (EDM) technology, in which gases such as air and oxygen are used as dielectrics and ultrasonic vibration is applied. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also possesses virtues of wide applications, high machining efficiency and simple tool electrodes and so on. The principle of UEDM in gas is introduced in this paper. Experiments have been carried out to study the effects of machining parameters on material removal rate (MRR), surface roughness of the workpiece and tool electrode wear ratio (TWR), and the experiments results have also been analyzed.

scholarly journals Analisa MRR, EWR, DOC terhadap Beberapa Material Elektroda pada Proses EDM Die Sinking

ROTASI ◽  
2019 ◽  
Vol 21 (1) ◽  
pp. 1
Author(s):  
Petrus Londa
Keyword(s):  
Wear Rate ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrode Wear ◽  
Conventional Machining

Electrical Discharge Machining (EDM) adalah non-conventional machining process. EDM dapat memotong semua jenis benda kerja yang bersifat penghantar listrik, terutama digunakan pada benda kerja yang sangat keras dan memiliki bentuk yang rumit, yang tidak dapat dipotong oleh mesin konvensional. Penelitian ini menggunakan metode Taguchi untuk menentukan variabel pemesinan yang secara signifikan mempengaruhi proses pemotongan pada beberapa material elektroda (tembaga, kuningan, alumunium) dan benda kerja dari bahan K460 (amutit S). Taguchi L25 Orthogonal standard arrays dan analysis of variance (ANOVA) dapat menentukan performa variabel pemotongan (PON, POFF, GAP, QDON, SERVO dan LT) dengan variabel yang diteliti adalah Electrode Wear Rate (EWR), Material Removal Rate (MRR) dan Diameter Overcut (DOC). Hasil dari penelitian ini ditampilkan dalam bentuk tabel-tabel dan grafik yang menunjukan variabel pemesinan yang signifikan mempengaruhi proses pemotongan sesuai dengan jenis material elektroda yang digunakan.

Machinability Evaluation by Single Electrical Discharge

2013 ◽  
Vol 371 ◽  
pp. 290-294 ◽  
Author(s):  
Lorelei Gherman ◽  
Ionut Palaghia ◽  
Laurenţiu Slătineanu
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Alloys ◽  
Tool Electrode ◽  
Thin Sheets ◽  
Process Factors

Electrical discharge machining is widely used in processing complex shaped parts. The method uses a tool electrode having a specific geometry, but the tool wear can affect such geometry in time. An affordable material for obtaining tool electrodes with complicated profiles can be electrolytic copper. Some issues appear when workpiece materials made also out of copper or copper alloys are processed, as the copper tool life span decreases. Machinability is the property of a material that indicates good process outcomes for the manufacturer, such as a high material removal rate and low tool wear. In order to determine some machinability indicators such as tool wear and material removal rate, a set of experiments were designed for single discharge machining using thin sheets of copper as tool electrodes and thin sheets of brass as test pieces, with workpiece thicknesses of 0.1 mm. The craters obtained after discharge were analyzed by means of a digital microscope. Based on these results, a statistical analysis was developed and the influence of input process factors was evaluated.

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