State of the art in powder-mixed electric discharge machining: A review

2016 ◽  
Vol 231 (14) ◽  
pp. 2511-2526 ◽  
Author(s):  
Gangadharudu Talla ◽  
S Gangopadhayay ◽  
CK Biswas
Keyword(s):  
Electric Discharge ◽  
Large Scale ◽  
Manufacturing Industry ◽  
Machining Process ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Good Surface ◽  
Powder Characteristics ◽  
Powder Particles ◽  
Major Application

Accomplishment of high machining rates along with good surface quality is a major concern in electric discharge machining process. Powder-mixed electric discharge machining in which suitable powder particles are impregnated in dielectric has gone forth as a potential solution to this problem. Nevertheless, challenges such as dielectric circulation, homogeneous blending of the powder particles in the dielectric, debris removal and quantity of the powder material required have to be addressed carefully before implementing this process on a large scale in the manufacturing industry. Extensive research in the field of electric discharge machining using powder-suspended dielectrics has started only in the recent years. In this article, a comprehensive review of the research going on in the field of powder-mixed electric discharge machining is presented. The emphasis is given on powder-mixed electric discharge machining mechanism, influence of powder characteristics and machining parameters on various responses. Some of the major application areas, variants of the basic powder-mixed electric discharge machining process and possibilities of further improvement are also discussed.

Effect of process parameters during electric discharge machining of maraging steel and optimization using Taguchi-DEAR method

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
MD Sameer ◽  
Anil Kumar Birru ◽  
G. Srinu ◽  
Ch Naresh
Keyword(s):  
Decision Making ◽  
Maraging Steel ◽  
Process Parameters ◽  
Electric Discharge ◽  
Crack Density ◽  
Machining Process ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Content Type ◽  
Tool Diameter

Purpose The electric discharge machining (EDM) involves electrons discharged from the electrode and machining progresses due to the removal of the material from the component. This a thermal-based machining process primarily used for hard to machine components with conventional methods. This process is used to make intricate cavities and contours. The fabricated part is the replica of the tool material with high surface finish and good dimensional accuracy. This study aims to evaluate the comprehensive effect of process parameters on electric discharge machining of maraging steel. Design/methodology/approach Multiple criteria Decision making (MCDM) techniques are used to select the best parameters by comparing several responses to achieve the desired goal. There are different MCDM techniques available for optimization of machining parameters. In the current investigation, multi-objective optimization by data envelopment analysis based ranking (DEAR) approach was used for machining Maraging C300 grade steel. Findings The Taguchi L9 runs were planned with process parameters such as current (Amp), Tool diameter (mm) and Dielectric pressure (MPa). The effect of process parameters on the responses, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were evaluated. High MRR is found at 15 A current, 14 mm tool diameter and dielectric pressure of 0.2 MPa. Optimum process parameters experiment showed reduced crack density. Originality/value An effort was made successfully to enhance the responses using the DEAR method and establish the decision making of selecting the optimal parameters by comparing the results obtained by machining maraging steel C300 grade.

Temperature Field Simulation of Anode Erosion in Electric Discharge Machining

2010 ◽  
Vol 455 ◽  
pp. 345-349
Author(s):  
B.C. Xie ◽  
Zhen Long Wang ◽  
Yu Kui Wang ◽  
Jing Zhi Cui
Keyword(s):  
Temperature Field ◽  
Electric Discharge ◽  
Material Removal ◽  
Machining Process ◽  
Model Parameters ◽  
Temperature Dependent ◽  
Electric Discharge Machining ◽  
Field Simulation ◽  
Simulation And Experiment ◽  
Anode Erosion

In this paper, a thermo-physical model of the electric discharge machining process using finite element method is presented. In this model, parameters such as convection, the latent heat and the thermal properties based on temperature dependent etc. are studied to predict the temperature distribution in the workpiece. The temperature field simulation and experiment were carried out by adopting parameters through optimum pulse curve, and amending the effects of recast layer, the simulation results amended shows a better agreement with experimental results, indicating a theoretical foundation for mechanism of material removal in EDM machining.

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