THE PHENOMENON OF SURFACE MODIFICATION BY ELECTRO-DISCHARGE COATING PROCESS: A REVIEW

2018 ◽  
Vol 25 (01) ◽  
pp. 1830003 ◽  
Author(s):  
SUJOY CHAKRABORTY ◽  
SIDDHARTHA KAR ◽  
VIDYUT DEY ◽  
SUBRATA KUMAR GHOSH
Keyword(s):  
Surface Modification ◽  
Substrate Surface ◽  
Tool Material ◽  
Machining Process ◽  
Machining Processes ◽  
Workpiece Material ◽  
Modification Technique ◽  
Inherent Nature ◽  
Conventional Machining ◽  
Edm Process

Electro-discharge machining (EDM) process is one of the most successful non-conventional machining processes for the last three to four decades in machining very hard materials which are tough to machine by conventional machining process. In the EDM process, besides the erosion of workpiece material, the inherent nature of the process leads to some tool material removal also. This nature of EDM process has been exploited by the researchers which led to the invention of Electro-discharge coating (EDC). EDC is a surface modification technique where tool material gets deposited on the substrate surface due to the sparking effect. It works on reverse polarity to that of EDM. A literature review based on the phenomenon of surface improvement by EDC process and also the future drifts of its application are shown in this paper.

Analysis of Performance Characteristics by Firefly Algorithm-Based Electro Discharge Machining of SS 316

2021 ◽  
pp. 45-54
Author(s):  
Premangshu Mukhopadhyay
Keyword(s):  
Magnetic Field ◽  
Tool Wear ◽  
Firefly Algorithm ◽  
Tool Material ◽  
Machining Process ◽  
Machining Performance ◽  
Machining Processes ◽  
Electro Discharge Machining ◽  
Conventional Machining ◽  
Edm Process

The process of combining two or more non-conventional machining processes to obtain the required machining performance is known as hybridisation. Hybrid electro discharge machining came into the picture of macro machining due to the requirement of more rapid machining process with improved efficiency of non-conventional machining process. The technique of vibration assisted EDM process did not prove to be successful due to some disadvantages like increase in tool wear for low melting and comparatively softer tool material. Therefore, a need for more advanced hybridised process has been realized to improve the overall machining efficiency specially circularity and radial overcut. A permanent magnetic field force assisted EDM process was carried out on SS 316 plate with tungsten carbide tool of 5 mm diameter. MRR, TWR, and diametral overcut have been optimized by firefly algorithm technique which showed satisfactory results. It has been found that tool wear and diametral overcut has been found to be reduced with magnetic field-assisted EDM than conventional EDM processes.

An Expert System Based on a Hybrid Multi-Criteria Decision Making Method for Selection of Non-Conventional Machining Processes

2015 ◽  
Vol 735 ◽  
pp. 41-49 ◽  
Author(s):  
Arash Azaryoon ◽  
Musa Hamidon ◽  
Ashraf Radwan
Keyword(s):  
Decision Making ◽  
Analytic Network Process ◽  
Reference Points ◽  
Multi Criteria Decision Making ◽  
Compromise Solution ◽  
Machining Processes ◽  
Workpiece Material ◽  
Topsis Technique ◽  
Conventional Machining ◽  
Selection Of

In this study, a knowledge-based system has been developed for selection of non-conventional machining processes using a hybrid multi-criteria decision making Method. This approach is a combination ofDEMATEL(Decision Making Trial and Evaluation Laboratory),ANP(Analytic Network Process) andVIKOR(VlseKriterijumska Optimizacija I Kompromisno Resenje, in Serbian, meaning Multi-criteria Optimization and Compromise Solution) methods which evaluates different types of quantitative and qualitative measures of performance and economic factors, and ultimately provides a set of capable processes in order of priority. Twelve machining processes, eight group of workpiece material and eighteen shape features have been investigated in this study. What separates this approach from others is that, this hybrid method considers the influence of factors in the network relation map as well as their relative importance. Moreover, unlike other popular ranking methods such as TOPSIS (Technique for Order Preference by Similarity to the Ideal Solution), it is not just based on two reference points, namely ideal and inferior points; instead, it proposes a compromise solution and not just a single ranking score. Observations have shown that the developed system works satisfactorily, yields acceptable results and makes accurate decisions as well. It also provides a comparative study among the alternative processes by utilizing graphical features for better analysis and judgment of acceptable alternatives.

A novel approach to machining process fault detection using unsupervised learning

2020 ◽  
pp. 095440542093755
Author(s):  
Thomas McLeay ◽  
Michael S Turner ◽  
Keith Worden
Keyword(s):  
Fault Detection ◽  
Unsupervised Learning ◽  
Tool Path ◽  
Cutting Tool ◽  
Novelty Detection ◽  
Cutting Parameters ◽  
Machining Process ◽  
Machining Processes ◽  
Workpiece Material ◽  
Data Set

The most common machining processes of turning, drilling, milling and grinding concern the removal of material from a workpiece using a cutting tool. The performance of machining processes depends on a number of key method parameters, including cutting tool, workpiece material, machine configuration, fixturing, cutting parameters and tool path trajectory. The large number of possible configurations can make it difficult to implement fault detection systems without having to train the system to a particular method or fault type. The research of this article applies a novel method to detect the changing state of a process over time in order to detect faulty machining conditions such as worn tools and cutting depth changes. Unlike studies in the previous literature in this domain, an unsupervised learning method is used, so that the method can be applied in production to unfamiliar processes or fault conditions. In the case presented, novelty detection is applied to a multivariate sensor feature data set obtained from a milling process. Sensor modalities include acoustic emission, vibration and spindle power and time and frequency domain features are employed. The Mahalanobis squared-distance is used to measure discordancy of each new data point, and values that exceed a principled novelty threshold are categorised as fault conditions.

Hybrid Non Conventional Machining of Glass - A Review

2019 ◽  
Vol 895 ◽  
pp. 8-14 ◽  
Author(s):  
Y. Nagaraj ◽  
N. Jagannatha ◽  
N. Sathisha
Keyword(s):  
Surface Finish ◽  
Machining Process ◽  
Machining Processes ◽  
Advantages And Disadvantages ◽  
Good Surface ◽  
Hard And Brittle Material ◽  
Good Surface Finish ◽  
Output Characteristics ◽  
Conventional Machining ◽  
Selection Of

Glass, being considered as hard and brittle material is very difficult to machine into desired shapes. The readily available conventional machining process does not provide good surface finish thus requires additional machining process. This paper reviews the different existing non conventional machining process accessible till today for the machining of glass materials. This paper also discusses the advantages and disadvantages of the existing non conventional machining processes. The various hybrid non conventional machining processes are also studied with focus on machining output characteristics like MRR, surface finish, tool wear rate. This paper summarizes the selection of hybrid non conventional machining processes for the various type of glass.

Electrical arc machining: Process capabilities and current research trends

2019 ◽  
Vol 233 (15) ◽  
pp. 5190-5200 ◽  
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.

COMPUTATIONAL FLUID DYNAMIC SIMULATION OF THE NANOELECTRICAL DISCHARGE MACHINING PROCESS

NANO ◽  
2011 ◽  
Vol 06 (06) ◽  
pp. 561-568 ◽  
Author(s):  
G. TAHMASEBIPOUR ◽  
Y. TAHMASEBIPOUR ◽  
M. GHOREISHI
Keyword(s):  
Pulse Duration ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fluid Dynamic ◽  
Average Power ◽  
Machining Process ◽  
Process Conditions ◽  
Machining Processes ◽  
Experimental Conditions ◽  
Edm Process

Electrical discharge machining (EDM) process is one of the advanced machining processes that can machine the various complex shapes from all conductor and semiconductor materials. Wide and diverse applications of Micro-EDM process in microfabrication and micro- to nano-miniaturization tendency is promising application of Nano-EDM process in nanofabrication. The Nano-EDM is a precise, sensitive and costly process. Therefore, simulation of nanocrater produced by each spark in this process prevents spending extra time and cost to perform Nano-EDM process through trial and error method. In this paper nanocrater machined by the Nano-EDM process on a gold nanofilm is simulated under practically experimental conditions. Radius, depth and volume of the nanocrater are evaluated versus process conditions (average power and pulse duration) and workpiece thickness (50 nm, 100 nm and 300 nm). It is observed that radius of the nanocrater is increased exponentially with increasing spark pulse duration. Also, depth, volume of the removed material from the workpiece surface and material removal rate (MRR) are increased with increasing consumed energy by each spark. By increasing thickness of the nanofilm, volume of the removed material and dimensions of the nanocrater are decreased.

scholarly journals Review on Effects of Electrode in Electrical Discharge Machining Process

2021 ◽  
Vol 8 (5) ◽  
pp. 91-95
Author(s):  
Nayan J. Patel
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Vital Role ◽  
Machining Process ◽  
Process Selection ◽  
Machining Processes ◽  
Electrically Conductive ◽  
Edm Process

Electrical Discharge Machining is one of the non-conventional machining processes used for electrically conductive material. It is widely used for manufacturing complicated parts which are tough to be produced by conventional manufacturing processes. It is based on thermoelectric energy between workpiece and electrode. Metal is removed by melting and vaporizing because of spark occurs in the gap between electrode and workpiece. Workpiece and electrode must have electrically conductive to generate a spark. The performance of the EDM process is largely depends on the electrode. Electrode is considered as tool in EDM process. Selection of the electrode material plays vital role in the EDM process. Different electrode materials have different properties. Hence, the performance of the EDM process changes with different materials. Researchers have used different materials as electrode to investigate the effects of materials and to improve the performance of EDM process. This paper reviews the research work carried out in the field of materials and manufacturing methods for electrodes in EDM process. Keywords: [EDM, Electrodes, Materials, Manufacturing Process].

scholarly journals Nature Inspired Metaheuristic Approach for Best Tool Work Combination for EDM Process

2021 ◽  
Author(s):  
Goutam Kumar Bose ◽  
Pritam Pain
Keyword(s):  
Removal Rate ◽  
Research Work ◽  
Tool Material ◽  
High Accuracy ◽  
Multi Criteria Decision Making ◽  
Workpiece Material ◽  
Die Steel ◽  
Modern Manufacturing ◽  
Artificial Neural Network Ann ◽  
Edm Process

As the modern day, the technologies are approaching with high accuracy at the same time with low material costing, non-traditional machining is very much essential to sustain in this modern manufacturing system. In this present research work Electric Discharge Machining (EDM) is used with different types of tools like Copper, Aluminium, and Brass are used while machining High Carbon High Chromium (HCHCr), Hot Die Steel (HDS) and Oil Hardened Nitride Steel (OHNS) workpiece material. This research work is aimed to find out the most efficient tool material for different workpiece materials while satisfying the contradictory objectives of high material removal rate (MRR) and low Tool Wear Rate (TWR). The experimental data are trained and validated by using Artificial Neural Network (ANN). Finally, the results obtained through Genetic Algorithm are hybridized with a Fuzzy- Multi Criteria Decision Making (MCDM) technique to obtain a single parametric combination of the process control parameters which satisfies these two contradictory objectives function simultaneously.

scholarly journals Impact of Different Electrolytes on the Machining Rate in ECM Process

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
K. G. Saravanan ◽  
R. Prabu ◽  
A. R. Venkataramanan ◽  
Eden Tekle Beyessa
Keyword(s):  
Metal Removal ◽  
Electrochemical Machining ◽  
Tool Material ◽  
Electrochemical Process ◽  
Machining Process ◽  
Complexing Agents ◽  
Workpiece Material ◽  
Electrolysis Process ◽  
Machining Rate ◽  
The Impact

Electrochemical machining is a nonconventional machining process in which the metal removal is achieved by the electricity and chemical solution known as an electrolyte. It is the reverse electrolysis process where the application of electricity facilitates the current travel in between anode and cathode. The mechanism of the ion movement is similar to the electrolysis process. Electrochemical machining (ECM) is a type of advanced machining process which employs electricity to perform the machining process on the workpiece. It is also known as a reverse electroplating process where metal removal is achieved instead of metal deposition on the metal surface. There are various parameters that affect the metal removal process in the ECM process, such as electrolyte, power supply, workpiece material, and tool material. The electrolyte is one of the key factors impacting the machining rate, surface finish, and reliability of the produced parts. In this project, a brief study is carried out regarding the electrochemical process and the electrolytes where the properties, functions, merits, and demerits are evaluated. The impact of the various electrolytes and their suitability for machining of various metals is also discussed. The findings of the effect produced by using the mixture of the electrolyte in the electrochemical machining process are discussed in this project. The effects of the complexing agents on the electrolyte and the electrochemical process as a whole are also reviewed.

scholarly journals Surface modification as a technique to improve inter-layer bonding strength in 3D printed cementitious materials

2019 ◽  
Vol 4 ◽  
pp. 33-38 ◽  
Author(s):  
Jolien Van Der Putten ◽  
Geert De Schutter ◽  
Kim Van Tittelboom
Keyword(s):  
Surface Roughness ◽  
Surface Modification ◽  
Bonding Strength ◽  
Substrate Surface ◽  
Cementitious Materials ◽  
Degree Of Hydration ◽  
Custom Made ◽  
Wire Brushing ◽  
Modification Technique ◽  
3D Printed

The structural capacity of 3D printed components mainly depends on the inter-layer bonding strength between the different layers. This bond strength is affected by many parameters (e.g. moisture content of the substrate, time gap, surface roughness,..) and any mismatch in properties of the cementitious material may lead to early failure. A common technique to improve inter-layer bonding strength between a substrate and a newly added layer is modifying the substrate surface. For the purpose of this research, a custom-made 3D printing apparatus is used to simulate the printing process and layered specimens with a different delay time (0 and 30 minutes) are manufactured with different surface modification techniques (wire brushing, addition of sand or cement and moisturizing substrate layer). The surface roughness was measured and the effect of the modification technique on the inter-layer-bonding strength was investigated. Results showed that the most effective way to increase the inter-layer bonding is increasing the surface roughness by a comb. This creates a kind of interlock system that will provide a higher inter-layer strength. The compressive strength is most influenced by the addition of cement, where the changing W/C-ratio will create a higher degree of hydration and consequently a higher strength.

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