Performance evaluation of different variants of jet electrochemical micro-drilling process

2016 ◽  
Vol 232 (3) ◽  
pp. 451-464 ◽  
Author(s):  
Harsha Goel ◽  
Pulak M Pandey
Keyword(s):  
Material Removal Rate ◽  
Direct Current ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Vibrations ◽  
Current Voltage ◽  
Ultrasonic Assisted ◽  
Micro Drilling ◽  
Direct Current Voltage ◽  
Pulsed Direct Current

The article describes fabrication of an experimental setup which could be used for electrochemical drilling process to produce micro-holes in a copper workpiece with its different variants, namely, jet electrochemical micro-drilling, air-assisted jet electrochemical micro-drilling, ultrasonic-assisted jet electrochemical micro-drilling, and pulsed direct current–jet electrochemical micro-drilling process. Process parameters like voltage, electrolyte concentration, interelectrode gap, and electrolyte pressure have been selected to find out their effects on the process responses, namely, hole taper and material removal rate in all the above process. Attachments for air assistance and ultrasonic vibration application have been fabricated and incorporated in the setup. The effects of ultrasonic vibrations and the pulsed direct current voltage on the process responses like material removal rate and hole taper have been investigated. The effect of application of ultrasonic vibrations on the electrolyte jet has been studied. The experimental findings of ultrasonic-assisted jet electrochemical micro-drilling were compared with the findings of jet electrochemical micro-drilling. Similarly, the findings of pulsed direct current–jet electrochemical micro-drilling were also compared with the results of pulsed direct current ultrasonic-assisted jet electrochemical micro-drilling experiments. It has been found that the ultrasonic vibrations have significant effect on the two process responses. From the results, it was observed that with the use of ultrasonic vibrations, the material removal rate has increased to significant level and the hole taper has been decreased than in jet electrochemical micro-drilling. Effects of the pulsed direct current voltage supply on jet electrochemical micro-drilling and (ultrasonic-assisted jet electrochemical micro-drilling) were also analyzed. Application of pulsed direct current voltage has improved the material removal rate and reduced the hole taper in jet electrochemical micro-drilling as well as in ultrasonic-assisted jet electrochemical micro-drilling. The experimental results concluded that ultrasonic assistance have generated the holes with greater material removal rate and lower hole taper and with continuous direct current and pulsed direct current voltage.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

Experimental Research on Ultrasonic Assisted Pulse Electrochemical Compound Finishing for Hard and Brittle Metal

2010 ◽  
Vol 42 ◽  
pp. 170-174
Author(s):  
Cheng Guang Zhang ◽  
Xue Ling Yang ◽  
Bo Zhao
Keyword(s):  
Particle Size ◽  
Surface Quality ◽  
Experimental Research ◽  
Material Removal Rate ◽  
Vibration Amplitude ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Ultrasonic Assisted ◽  
Metal Materials

The experiment of ultrasonic assisted pulse electrochemical compound finishing is carried in this paper. The machining principle of the compound finishing is discussed in this paper. Processing experiments of compound finishing are carried out to study the effects of the main processing para- meters, including the particle size, the ultrasonic vibration amplitude, the minimum gap between the tool head and workpiece and the pulse voltage, on the material removal rate and the surface quality for hard and brittle metal materials. The curves of the corresponding relationships are also obtained. The study indicates that the processing velocity, machining accuracy and surface quality can be improved under the compound finishing, obtaining the processing technology conductions of the compound finishing. Introductions

scholarly journals A Role of cryogenic in Wire cut EDM process

2020 ◽  
Vol 184 ◽  
pp. 01067
Author(s):  
Kosaraju Satynarayana ◽  
Kumkuma Rajkiran ◽  
Pujari Anil kumar ◽  
D Chakradhar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Performance Characteristics ◽  
Machining Processes ◽  
Current Voltage ◽  
Tension Wire ◽  
Wedm Process

Novel techniques are being focused on the enrichment of the performance characteristics under different machining processes. Cryogenic is one of such novel practices that tunes the surface integrity with vast variations with the traditional machining processes. Dimensional accuracy, surface roughness, material removal rate with less reduction in scrap of material is one of the prior targets of production process. Wire cut Electro Discharge Machining (WEDM) is one method that satisfy with upgrading performance characteristics. In order to step-up these performance characteristics in attaining superior quality, cryogenics practices have collaborated with the WEDM process. Present paper deals with the reviews of the researchers that have been performed over cryogenic treated WEDM process. Effect of performance characteristics like pulse on, pulse off, current, voltage, wire tension, wire feed is discussed with relation to material removal rate, tool wear rate and surface roughness evolved. Key concept of paper is to include the research ideology with best feasible techniques that can prevail in production practice in order of contribute to the forthcoming researches in industrial and production departments.

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics

2019 ◽  
Vol 233 (14) ◽  
pp. 2515-2530 ◽  
Author(s):  
R Rajeswari ◽  
MS Shunmugam
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Machining Process ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Pulse On Time

Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a consequential reduction in cycle time. Powder mix and ultrasonic assistance are employed in the electrical discharge machining process to create gap conditions favoring material removal. In the present work, experiments are carried out on hardened D3 die steel using full-factorial design based on three levels of voltage, current and pulse on time. The gap phenomena in graphite powder-mixed and ultrasonic-assisted rough electrical discharge machining are studied using a detailed analysis of pulse shapes and their characteristic trains. Two new parameters, namely, energy expended over a second ( E) and performance factor ( PF) denoting the ratio of energy associated with sparks to total discharge energy, bring out gap conditions effectively. In comparison with the conventional electrical discharge machining for the selected condition, it is seen that the graphite powder mixed in the dielectric enhances the material removal rate by 20.8% with E of 215 J and PF of 0.227, while these values are 179.8 J and 0.076 for ultrasonic-assisted electrical discharge machining with marginal reduction of 3.9%. Cross-sectional images of workpieces also reveal the influence of electrical discharge machining conditions on the machined surface. The proposed approach can be extended to different powder mix and ultrasonic conditions to identify condition favoring higher material removal.

Modelling and simulation of ultrasonic-assisted jet electrochemical micro drilling process

2019 ◽  
Vol 233 (12) ◽  
pp. 4199-4212
Author(s):  
Harsha Goel ◽  
Usharani Rath ◽  
Pulak M Pandey
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Modelling And Simulation ◽  
Drilling Process ◽  
Ultrasonic Assisted ◽  
Micro Holes ◽  
Micro Drilling ◽  
Experimental Findings ◽  
Electrolyte Jet

Ultrasonic-assisted jet electrochemical micro drilling is an advanced variant of electrochemical machining to drill micro holes quickly and efficiently. The present article deals with the modelling and simulation of the integration of ultrasonic vibration with the conventional jet electrochemical micro drilling process. Multi-physics-based modelling and simulation approach has been used in the present work. The flow pattern of electrolyte jet was analysed for both jet electrochemical micro drilling and ultrasonic-assisted jet electrochemical micro drilling processes. The simulation results were validated with the previous experimental findings of ultrasonic-assisted jet electrochemical micro drilling process. It was found that the material removal rate (MRR) improved significantly as the ultrasonic wave got superimposed onto the electrolyte jet. In addition to that, voltage and concentration of the electrolyte also played vital roles in improving the MRR.

A Study on Grinding Tungsten Carbide with Ultrasonic Assisted

2013 ◽  
Vol 797 ◽  
pp. 374-381
Author(s):  
Pei Lum Tso ◽  
Chao Chun Tseng
Keyword(s):  
Tungsten Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Temperature ◽  
Limited Range ◽  
Machining Process ◽  
Grinding Wheel ◽  
Hard Alloys ◽  
Ultrasonic Assisted

In order to cope with high demanded industry requirements. The super-hard alloys such as Tungsten Carbide have been widely used in aerospace and defense industries. So far, the grinding operation is still the most popular machining process being used to cut these materials in shape. But, owing to the nature of these materials mechanical properties, always made it very difficult to grind as well as to cut. Nevertheless, the allowable grinding parameters are resisted to very limited range and always require use very expensive super abrasive grinding wheel. Recently, study by many researchers show that the ultrasonic assist grinding had the advantage of higher material removal rate, less cutting force and lower cutting temperature. In the mean time, the tool life had been improved greatly. In this study, the conventional GC grinding wheel was used in the experiments to study the material removal rate; grinding force; surface roughness as well as specific grinding energy with and without the ultrasonic assist. The results show that these difficult-to-cut materials can be ground easier with proper ultrasonic assist and low-priced grinding wheel.

scholarly journals Ultrasonic-Assisted Cutting: A Beneficial Application for Temperature, Torque Reduction, and Cutting Ability Improvement in Deep Drilling of Al-6061

2018 ◽  
Vol 8 (10) ◽  
pp. 1708 ◽  
Author(s):  
Ngoc-Hung Chu ◽  
Van-Du Nguyen ◽  
The-Vinh Do
Keyword(s):  
Axial Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
High Speed Steel ◽  
Deep Drilling ◽  
Workpiece Temperature ◽  
Al 6061 ◽  
Positive Effects ◽  
Ultrasonic Assisted

This paper presents an experimental study of the positive effects of vibration-assisted deep drilling of aluminum alloy Al-6061. The four most important evaluation criteria in drilling—machinability, workpiece temperature, torque, and material removal rate—were chosen to be investigated. Holes with a depth-to-diameter ratio of 13 were drilled by high speed steel (HSS) twist drill bits of 3 mm diameter, using both methods of conventional drilling (CD) and ultrasonic-assisted drilling (UAD). Three levels of axial force of 6 kgf, 9 kgf, and 12 kgf were kept constant for each pair of comparison experiments. It was found that workpiece temperature and torque not only changed from one drill to the other, but were also dependent on the hole depth being drilled. Comparisons were made in-pair between CD and UAD under the same axial force and at the same order of hole numbers. The result shows that the material removal rate with UAD was up to 3.5 times higher than that with CD and the average workpiece temperature and torque in UAD were reduced by 3.5 and 6 times, respectively. Moreover, tool life in UAD was observed to increase from 2.5 to 5 times, in terms of number of holes drilled, compared to that in CD.

Experimental Investigation of Drilling Incorporated Electrochemical Discharge Machining

2014 ◽  
Author(s):  
Baoyang Jiang ◽  
Shuhuai Lan ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Drilling Process ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Drilling

Electrochemical discharge machining (ECDM) is a non-conventional micromachining technology, and is highlighted for non-conductive brittle materials. However, the outcomes of ECDM have many restrictions in application due to limitations on efficiency, accuracy, and machining quality. In this paper, a drilling incorporated ECDM process is presented and analyzed to enhance material removal rate in ECDM drilling process. Incorporating micro-drilling into ECDM significantly increases the rate of material removal, especially in deep hole drilling. As fundamentals of the machining process, material removal mechanisms have been investigated to account for the increment in material removal rate by incorporating micro-drilling. Vibration of tool electrode, induced by a piezo-actuator, was introduced to further enhance material removal rate. Quantitative studies were conducted to determine the appropriate process parameters of drilling incorporated ECDM with tool vibration.

Grinding of Soft Steel with Assistance of Ultrasonic Vibrations

2008 ◽  
Vol 389-390 ◽  
pp. 271-276 ◽  
Author(s):  
Taghi Tawakoli ◽  
Bahman Azarhoushang ◽  
Mohammad Rabiey
Keyword(s):  
Material Removal Rate ◽  
Specific Energy ◽  
Material Removal ◽  
Thermal Damage ◽  
Removal Rate ◽  
Harmful Effect ◽  
Grinding Forces ◽  
Machining Processes ◽  
Ultrasonic Assisted ◽  
Conventional Grinding

Compared to other machining processes, conventional grinding has a low material removal rate and involves high specific energy. A major part of the specific energy in grinding is changed to heat which makes harmful effect on surface quality. A recent and promising method is the use of ultrasonic assistance to increase the material removal rate along with decreasing the thermal damage on the workpiece and reducing cutting forces. The advantages of Ultrasonic Assisted Grinding (UAG) were proved mostly for the brittle material. Our investigations show the improvement on the surface roughness, reduction of the grinding forces and thermal damage in case of using UAG comparing to Conventional Grinding (CG) for a soft material of 100Cr6. The designed and developed ultrasonically vibrated workpiece holder and the experimental investigation show a decrease of up to 40% of normal grinding forces.

Sign in / Sign up

Export Citation Format

Share Document