Experimental study of an electrostatic field–induced electrolyte jet electrical discharge machining process

2015 ◽  
Vol 231 (10) ◽  
pp. 1752-1759 ◽  
Author(s):  
Zhang Yaou ◽  
Han Ning ◽  
Kang Xiaoming ◽  
Zhao Wansheng ◽  
Xu Kaixian
Keyword(s):  
Electrostatic Field ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Cyclic Process ◽  
Tool Electrode ◽  
Series Of Experiments ◽  
Current Detection ◽  
Electrolyte Jet

In this study, a new electrostatic field–induced electrolyte jet electrical discharge machining method has been proposed, which can automatically generate the tool electrode. Then, a series of experiments have been carried out to reveal the machining mechanism and test the machining ability of this method. The continuous observation experiments and the online current detection experiments have demonstrated that the electrolyte jet discharge machining is a pulsing, dynamic and cyclic process. Moreover, the 20-min time long reverse polarity experiments on the silicon surface have revealed that the machining is an electrical discharge machining process during the negative polarity machining; however, in the positive polarity machining, it is a hybrid electrical discharge machining and electrochemical machining process. Furthermore, the craters as small as 2 µm in diameter on stainless steel and silicon are produced by this electrolyte jet electrical discharge machining, which has proved the micro-machining ability of this method.

Small Diameter External Cylindrical Surfaces Obtained by Ram Electrical Discharge Machining

2014 ◽  
Vol 611-612 ◽  
pp. 650-655 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Irina Besliu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Analysis ◽  
Electrical Discharge Machine ◽  
Small Diameter ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Electrical Discharges ◽  
Pulse On Time

Electrical discharge machining uses the pulse electrical discharges generated between the closest asperities existing on the workpiece surface and the active surface of the tool electrode in dielectric fluid. Essentially, some distinct electrical discharge machining schemas could be used in order to obtain cylindrical external surfaces; within this research, one preferred a machining schema based on the use of a cooper plate in which there were small diameter holes, by taking into consideration the existence of a ram electrical discharge machine. The results of the machining process analysis were presented. A thin copper was considered to be used as tool electrode, in order to diminish the spurious electrical discharges, able to generate shape errors of the machined surface. Some experimental researches were developed by changing the sizes of the process input parameters. As output factors, the test piece and tool electrode masses decreases were considered. Power type empirical mathematical models were determined, in order to highlight the influence exerted by the pulse on time, off time and machining process duration on the output parameters values.

Electrical Discharge/Electrochemical Hybrid Machining Based on the Same Machine and Tool Electrode

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Ryoichiro Kishi ◽  
Jiwang Yan
Keyword(s):  
Electrical Discharge ◽  
Surface Defects ◽  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Hybrid Process ◽  
Tool Electrode ◽  
Alignment Error ◽  
Rapid Fabrication ◽  
Finishing Process

Abstract Electrical discharge machining (EDM) causes surface defects such as resolidified layer and microcracks, and a finishing process is usually needed to remove these defects. In this paper, a hybrid process was proposed where electrochemical machining (ECM) was performed as a finishing process after EDM using the same tool electrode on the same machine. By using two kinds of disk-type rotary electrodes, rectangular grooves and grooves with convex inner structures were fabricated. Surface topography were investigated by using scanning electron microscope (SEM), energy dispersive X-ray spectrometry (EDX), and laser-probe surface profilometer. The material removal mechanism of resolidified layers was clarified. The surface roughness of the rectangular groove was improved from 3.82 μm Ra to 0.86 μm Ra after ECM. Electrode rotation was effective for flushing electrolytic products when fabricating inner structures. As there is no need for exchanging tools and machines, tool alignment error can be prevented and productivity can be improved. Therefore, the proposed EDM/ECM hybrid process contributes to rapid fabrication of microscale products with high surface integrity.

An Experimental Study of the Phenomenon of Surface Alloying by EDM Process Using Inconel Tool Electrode

2013 ◽  
Author(s):  
Sanjeev Kumar
Keyword(s):  
Experimental Study ◽  
Surface Properties ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Plasma Channel ◽  
Machining Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Surface Alloying ◽  
Machining Conditions

Electrical Discharge Machining (EDM) has emerged as a very important machining process due to its numerous advantages. It is extensively used by the die and toolmaking industry for the accurate machining of complex internal profiles. Although EDM is essentially a material removal process, it has been used successfully for improving the surface properties of the work materials after machining. As the dissolution of the electrode takes place during the process, some of its constituents may alloy with the machined surface under appropriate machining conditions. Additive powders in the dielectric medium may form part of the plasma channel in the molten state and produce similar alloying effect. The breakdown of the hydrocarbon dielectric under intense heat of the spark contributes carbon to the plasma channel. Sudden heating and quenching in the spark region also alters the surface properties. This paper reports the results of an experimental study into electrical discharge machining of H13 hot die steel with Inconel (an alloy of chromium, nickel and iron) tool electrode under machining conditions favouring high electrode wear. The results show improvement in micro-hardness after machining by as much as 88%. Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) analysis of the machined surfaces show transfer of chromium and nickel from the tool electrode. Both these elements form intermetallic compounds as well as solid solution with iron and strengthen it. It was found that percentage of chromium increased from 5.39% to 6.52% and that of nickel increased from 0.19% to 4.87%. The favourable machining conditions for surface alloying were found to be low value of peak current, shorter pulse on-time, longer pulse off-time and negative polarity of the tool electrode.

Experimental investigation of the governing parameters of the electrostatic field–induced electrolyte jet micro electrical discharge machining on the silicon wafer

2017 ◽  
Vol 232 (12) ◽  
pp. 2201-2209 ◽  
Author(s):  
Yaou Zhang ◽  
Ning Han ◽  
Xiaoming Kang ◽  
Shuhuai Lan ◽  
Wansheng Zhao
Keyword(s):  
Silicon Wafer ◽  
Electrostatic Field ◽  
Electrical Discharge ◽  
Electrolyte Concentration ◽  
Electrical Discharge Machining ◽  
Micro Electrical Discharge Machining ◽  
Crater Size ◽  
Single Discharge ◽  
Inner Diameter ◽  
Electrolyte Jet

Electrostatic field–induced electrolyte jet micro electrical discharge machining relies on the cyclic and pulsating electrical discharge between the tip of the fine jet, and the workpiece to remove the debris. To further explore the processing characteristics, the single-pulsating discharge experiments have been carried out with the NaCl electrolyte as the jet solution and the silicon wafer as the workpiece. The experimental results have shown that the crater size after a single electrostatic field–induced electrolyte jet discharge increases with an increase in the voltage applied between the nozzle and the workpiece and increases with an increase in the electrolyte concentration, but declines with an increase in the nozzle-to-workpiece distance. Moreover, the crater size has no direct relationship with the machining polarity, but slightly declines with an increase in the inner diameter of the nozzle. Finally, the conclusion that the parameters which influence the charge density on the electrolyte jet surface can determine the diameter of the single-discharge crater has also been drawn.

Scanning Micro-Electrochemical Machining Process for V-Shaped Grooves

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Hao Zhong ◽  
Hao Tong ◽  
Zhiqiang Wang ◽  
Yong Li ◽  
Yubin Pu
Keyword(s):  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Microfluidic Chips ◽  
Long Distance ◽  
High Surface Quality ◽  
Micro Electrical Discharge Machining ◽  
The Given

Abstract Microstructures determine flow properties of microfluidic chip. Micromold forming is an effective method to realize mass manufacturing of microfluidic chips. This requires to machine some kind of special microstructure of high surface quality on a metal/alloy workpiece. Micro V-shaped grooves are the typical microstructures of the chip micromolds used for controlling microfluid or weld packaging. In this research, a scanning micro-electrochemical machining (ECM) process of V-shaped grooves is proposed using a tool electrode fabricated by micro–electrical discharge machining (EDM) on-machine. Theoretical and experimental research was conducted for achieving the V-shaped grooves with a given angle on die steel. A long-distance V-shaped groove with the given angle of 67 deg and the depth of 125 μm was successfully machined.

Optimization of the Wire Electrical Discharge Machining Process Using Grey Relational Analysis and Taguchi Method

2015 ◽  
Vol 651-653 ◽  
pp. 738-743
Author(s):  
Oana Dodun ◽  
Vasile Merticaru ◽  
Laurenţiu Slatineanu ◽  
Margareta Coteaţă
Keyword(s):  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Wire Electrical Discharge Machining ◽  
Relational Analysis ◽  
The Wire ◽  
Grey Relational

The wire electrical discharge machining is a machining method able to allow detaching parts from plates type workpieces as a consequence of electrical discharges developed between workpiece and wire tool electrode found in a motion along its axis; there is also a work motion along the contour to be obtained. There are many factors able to exert influence on the sizes of parameters of technological interest. On the other hand, there are various methods that can be used in order to establish the optimal combination of the input factors, so that obtaining of machining best results is possible. When there are many process output factors, a problem of multiobjective optimization could be formulated. The Grey relational analysis method and the Taguchi method could be applied in order to optimize the wire electrical discharge machining process, when various criteria having distinct significances are considered. An experimental research was designed and developed in order to optimize the wire electrical discharge cutting of parts made of an alloyed steel, by considering six input factors: test piece thickness, pulse on time, pulse off time, wire axial tensile, current intensity and travelling wire electrode speed. As output parameters, one took into consideration surface roughness, wire tool electrode massic wear, cutting speed along the contour to be obtained. 16 experiments were developed in accordance with the requirements specific to a Taguchi table L16. The results of experiments were processed by means of Grey relational analysis method and Taguchi method.

Machining of External Cylindrical Surfaces on a RAM Electrical Discharge Machine

2013 ◽  
Vol 554-557 ◽  
pp. 1800-1805 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Irina Besliu ◽  
Lorelei Gherman ◽  
Oana Dodun
Keyword(s):  
Test Piece ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Machining Process ◽  
Tool Electrode ◽  
Shape Error ◽  
Machined Surface ◽  
Electrode Tool ◽  
Shape Errors

As other nonconventional machining methods, the electrical discharge machining is applied when the workpieces materials are difficult to be machined by classical machining methods or the surfaces could not be obtained in efficient conditions by classical machining methods. Such a situation could appear, for example, when test pieces must be separated from materials whose machining by classical methods is difficult. Taking into consideration the necessity to detach a cylindrical test piece from a workpiece made of a high resistance metallic alloy, the problem of using the electrical discharge machining was formulated. An initial experimental test by using the common work motion of the tool electrode from up to down highlighted high shape errors, due to the accumulation in the work zone of the particles detached from the workpiece and from the tool electrode, as a consequence of electrical discharge machining process. A second set of experiments were developed, placing the test piece over the electrode tool and ensuring a work motion of workpiece from up to down; in this situation, a diminishing of the shape error was noticed. The second set of experiments highlighted a relatively reduced conicalness of the machined surface and a low decrease of the machining speed. as the penetration depth of the tool electrode in the workpiece increases, too.

Experimental Investigation on Manufacturing and Environmental Aspects of Electrical Discharge Machining Process Using Graphite Electrode

2012 ◽  
Vol 433-440 ◽  
pp. 655-659
Author(s):  
S. Thiyagarajan ◽  
S.P. Sivapirakasam ◽  
Jose Mathew ◽  
M. Surianarayanan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Electrode ◽  
Environmental Aspects ◽  
Influence Of Process Parameters ◽  
Peak Current ◽  
Aerosol Emission

This paper presents a study on the influence of process parameters on the manufacturing and environmental aspects of die sinking electrical discharge machining process using graphite as the tool electrode. This investigation included peak current, pulse duration, dielectric level and flushing pressure as the input parameters and aerosol emission rate, material removal rate and tool wear rate as the output parameters. The experiments were planned according to the Taguchi L9 orthogonal array. The effects of process parameters on the output responses were analyzed using main effect plots. Peak current was the most significant process parameter. A discussion on the optimization of process parameters is also presented in this paper.

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