A REVIEW OF RECENT METHODS FOR TOOL WEAR REDUCTION IN ELECTRICAL DISCHARGE MACHINING

2020 ◽  
Vol 27 (12) ◽  
pp. 2030002 ◽  
Author(s):  
AMOLJIT SINGH GILL ◽  
SANJEEV KUMAR ◽  
JUJHAR SINGH ◽  
VIVEK AGGARWAL ◽  
SHUBHAM SHARMA
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Machining Processes ◽  
Dielectric Characteristics ◽  
Coated Tool ◽  
Ultrasonic Assisted ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most explored nonconventional machining processes due to its ability to machine intricate shapes on conductive materials. However, tool wear is one of the major challenges in the EDM process as it directly affects the accuracy of machining, surface roughness, reproduction of geometrical characteristics on the workpiece and cost of the process. Lots of work have been done to minimize the tool wear by improving the discharge conditions by controlling the EDM process parameters, varying the dielectric characteristics, powder-mixed dielectric methods and ultrasonic-assisted methods. However, minimizing the tool wear by the above approaches also constrains the material removal rate from the workpiece and accuracy of the process. This review highlights the efforts done by the researchers to improve tool wear by recently developed techniques or modifications. Researches available in the field of using treated tool electrode, cooled tool electrode, coated tool electrode, noble tool materials and other techniques are highlighted.

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.

Productivity of EDM Process Assisted by Ultrasonic Waves

2011 ◽  
Vol 175 ◽  
pp. 157-160 ◽  
Author(s):  
Jian Wu Yu ◽  
Lucjan Dabrowski ◽  
Shao Hui Yin ◽  
Zbigniew Lechniak
Keyword(s):  
Experimental Investigation ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ultrasonic Waves ◽  
Machining Efficiency ◽  
Hybrid Machining ◽  
Ultrasonic Assisted ◽  
Edm Process

Ultrasonic assisted electrical discharge machining (USEDM) is one of hybrid machining methods based on the EDM process. The effects of ultrasonic waves on EDM process were analyzed and the experimental investigation of productivity of steel induced by USEDM was reported. Results indicated that ultrasonic waves and cavitation played an important role in improving the flushing and machining efficiency during USEDM. And the material removal rate of EDM assisted by ultrasonic waves was improved greatly.

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.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

CHARACTERIZATION OF ZrB2-SiC COMPOSITES WITH AN ANALYTICAL STUDY ON MATERIAL REMOVAL RATE AND TOOL WEAR RATE DURING ELECTRICAL DISCHARGE MACHINING

2016 ◽  
Vol 40 (3) ◽  
pp. 331-349 ◽  
Author(s):  
S. Sivasankar ◽  
R. Jeyapaul
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Relative Density ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Tool Materials

This research work concentrates on Electrical Discharge Machining (EDM) performance evaluation of ZrB2- SiC ceramic matrix composites with different tool materials at various machining parameters. Monolithic ZrB2 possesses lower relative density (98.72%) than composites. ZrB2 with 20 Vol.% of SiC possesses 99.74% of the relative density with improved hardness values. Bend strength and Young’s modulus increase with SiC addition until it reaches 20 Vol% and then decreasing. EDM performance on tool materials of tungsten, niobium, tantalum, graphite and titanium at various levels of pulse on time and pulse off time are analyzed. Graphite produces the best Material removal rate (MRR) for all the workpieces. Tool wear rate decreases with melting point and thermal conductivity of the tool material.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

Electrical Discharge Coating by Copper-Tungsten Composite Electrode Prepared by Powder Metallurgy Route

2018 ◽  
pp. 195-224 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Harmony Search ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Weight Percentage ◽  
Material Deposition ◽  
Edm Process ◽  
Powder Metallurgy Route

Electrical discharge machining (EDM), a thermo-mechanical machining process, is used in producing complicated intrinsic cavity in difficult-to- machine materials with excellent surface finish. One of the major disadvantage of EDM process is the tool wear, which can be used advantageously for coating purpose. Coating is a unique method of EDM process by the use of electrode prepared via powder metallurgy route. Copper and tungsten powders in weight percentage of 30 and 70 respectively are used for the preparation of the tool electrode by varying the PM process parameters like compaction pressure and sintering temperature. The substrate on which coating is made is chosen as AISI 1040 stainless steel with EDM oil as the dielectric fluid. During coating, influence of parameters like discharge current, duty cycle and pulse-on-time on material deposition rate, tool wear rate and radial under deposition are studied. To find out the best parametric combination Grey Relational Analysis method combined with Harmony Search algorithm has been employed.

A Multiobjective Genetic-Algorithm-Based Optimization of Micro-Electrical Discharge Drilling

2021 ◽  
pp. 676-698
Author(s):  
Deepak Rajendra Unune ◽  
Amit Aherwar
Keyword(s):  
Genetic Algorithm ◽  
Process Parameters ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining ◽  
Electrical Discharge Drilling ◽  
Machining Rate

Inconel 718 superalloy finds wide range of applications in various industries due to its superior mechanical properties including high strength, high hardness, resistance to corrosion, etc. Though poor machinability especially in micro-domain by conventional machining processes makes it one of the “difficult-to-cut” material. The micro-electrical discharge machining (µ-EDM) is appropriate process for machining any conductive material, although selection of machining parameters for higher machining rate and accuracy is difficult task. The present study attempts to optimize parameters in micro-electrical discharge drilling (µ-EDD) of Inconel 718. The material removal rate, electrode wear ratio, overcut, and taper angle have been selected as performance measures while gap voltage, capacitance, electrode rotational speed, and feed rate have been selected as process parameters. The optimum setting of process parameters has been obtained using Genetic Algorithm based multi-objective optimization and verified experimentally.

Fabrication and experimental investigation of magnetic field assisted powder mixed electrical discharge machining on machining of aluminum 6061 alloy

2019 ◽  
Vol 233 (12) ◽  
pp. 2283-2291 ◽  
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Pulse On Time

Magnetic field assisted powder mixed electrical discharge machining is a hybrid machining process with suitable modification in electrical discharge machining combining the use of magnetic field and fine powder in the dielectric fluid. Aluminum 6061 alloy has found highly significance for the advanced industries like automotive, aerospace, electrical, marine, food processing and chemical due to good corrosion resistance, high strength-to-weight ratio, ease of weldability. In this present work, magnetic field assisted powder mixed electrical discharge machining setup was fabricated and experiments were performed using one factor at a time approach for aluminum 6061 alloy. The individual effect of machining parameters namely, peak current, pulse on time, pulse off time, powder concentration and magnetic field on material removal rate and tool wear rate was investigated. The effect of peak current was found to be dominant on material removal rate and tool wear rate followed by pulse on time, powder concentration and magnetic field. Increase in material removal rate and tool wear rate was observed with increase in peak current, pulse on time and a decrease in pulse off time, whereas, for material removal rate increases and tool wear rate decreases up to the certain value and follow the reverse trend with an increase in powder concentration. Material removal rate was increased and tool wear rate was decreased with increase in magnetic field.

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