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.

Vibration-assisted electrical arc machining of 10% B4C/Al metal matrix composite

2019 ◽  
Vol 234 (6) ◽  
pp. 1156-1170
Author(s):  
Shrihar Pandey ◽  
Pankaj K Shrivastava
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrical Arc ◽  
Unconventional Machining

To shape advanced engineering materials, many unconventional machining processes have been developed. Electrical discharge machining is such an unconventional machining process which is very popular nowadays but it is limited by poor material removal efficiency. Electrical arc machining is another unconventional machining process which is quite similar to electrical discharge machining and is now gaining attention from research fraternity due to its high material removal efficiency. In the present research, an innovative unconventional machining process known as vibration-assisted electrical arc machining has been developed. The performance of vibration-assisted electrical arc machining has been evaluated during machining of Al–B4C metal matrix composite by considering peak current, flushing velocity of dielectric and tool vibrations as input control factors. The quality characteristics considered were material removal rate, tool wear rate, relative electrode wear rate and surface roughness. It has been observed that vibration-assisted electrical arc machining results in approximately 3000% more material removal rate as compared to conventional electrical discharge machining during machining of Al–B4C metal matrix composite. The effects of various input control factors on output parameters have also been discussed. Further modelling and optimization of the process parameters has also been done by artificial intelligence approach.

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.

EXPERIMENTAL INVESTIGATION OF MICRO-EDM OPERATION IN INCONEL 718

2021 ◽  
pp. 2150102
Author(s):  
MAYANK CHOUBEY ◽  
K. P. MAITY
Keyword(s):  
Experimental Investigation ◽  
Inconel 718 ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Machining Processes ◽  
Machining Time ◽  
Machine Material ◽  
Micro Holes ◽  
Unconventional Machining

The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.

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.

Experimental Study of Micromachining on Borosilicate Glass Using CO2 Laser

2020 ◽  
Vol 143 (5) ◽  
Author(s):  
Vishnu Vardhan Posa ◽  
Murali Sundaram
Keyword(s):  
Laser Scanning ◽  
Laser Energy ◽  
Removal Rate ◽  
Scanning Speed ◽  
Machining Process ◽  
Laser Machining ◽  
Glass Work ◽  
Workpiece Material ◽  
Laser Parameters ◽  
Wide Range

Abstract Laser beam machining (LBM) is a versatile process that can shape a wide range of engineering materials such as metals, ceramics, polymers, and composite materials. However, machining of glass materials by LBM is a challenge as most of the laser energy is not absorbed by the surface. In this study, an attempt has been made to increase the absorptivity of the glass material by using a coating on the surface of the material. Glass has been used in this study because of its extensive applications in the micro-opto-electro-mechanical systems. The optimal machining depends on both laser parameters and properties of the workpiece material. There are number of laser parameters that can be varied in the laser machining process. It is difficult to find optimal laser parameters due to the mutual interaction of laser parameters. A statistical study based on design of experiment (DoE) has been made to study the effect of coating and parameters like laser power, laser scanning speed, angle of inclination of the workpiece on depth of the slot, width of the slot, aspect ratio, and material removal rate (MRR) in the laser machining process using 2k factorial design and analysis of variance (ANOVA). On an average, four times increase in depth of the slot, two times increase in width of the slot and seven times increase in the MRR were observed in the glass samples with coating when compared to uncoated glass work samples.

Reduction of Vibrations due to Unbalance with Anti-Vibration Clearance Angle in High Speed Milling

2016 ◽  
Vol 836-837 ◽  
pp. 161-167
Author(s):  
Anna Thouvenin ◽  
Xin Li ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Machining Process ◽  
High Speed Machining ◽  
Machining Processes ◽  
High Speed Milling ◽  
Clearance Angle ◽  
Fast Solution ◽  
Considerable Problem

High speed milling is one of the most commonly used machining processes in many fields of the industry. It is regarded as a simple and fast solution to achieve a high material removal rate, which allows an important production of parts. Unbalance is a problem in any machining process but becomes a considerable problem when reaching high speed machining. The vibrations due to an unbalanced tool or tool holder can result in a poor surface quality and a damaged tool. The damping of the vibrations can be achieved with a specially designed tool showing an anti-vibration clearance angle. This paper shows the influence of the anti-vibration clearance angle by a computational model and a set of experiments to see if it can reduce or suppress the vibrations due to unbalance in high speed milling.

Multi-objective optimization of process parameters involved in micro-finishing of Al/SiC MMCs by abrasive flow machining process

2016 ◽  
Vol 232 (4) ◽  
pp. 319-332 ◽  
Author(s):  
Mittal Sushil ◽  
Kumar Vinod ◽  
Kumar Harmesh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Removal Rate ◽  
Fluid Pressure ◽  
Base Material ◽  
Machining Process ◽  
Workpiece Material ◽  
Abrasive Flow Machining ◽  
Optimization Of Process Parameters ◽  
Desirability Approach

It is hard to finish small slots in composite materials which have wide applications nowadays in aerospace, automobile and medical. Abrasive flow machining is a process that is suitable for such type of operations. In this paper, by using abrasive flow machining, investigation of SiC Metal Matrix Composites (MMCs) with aluminum as base material has been done. Material removal rate and change in surface roughness (ΔRa) are taken as response parameters. Response surface methodology has been applied to find out the effect of input parameters like fluid pressure, percentage of oil in media, grit size, concentration of abrasives, workpiece material and number of cycles on response parameters. Box–Behnken design has been preferred. Response parameters have been optimized using the desirability approach in response surface methodology. The significance of different parameters is identified using analysis of variance. An optimum combination of parameters is designed for the process. Furthermore, specimens were examined and analyzed using scanning electron microscope and X-ray diffraction techniques.

Comparative Study on Parametric Analysis of μEDM of Non-Conductive Ceramics

2014 ◽  
Vol 611-612 ◽  
pp. 693-700 ◽  
Author(s):  
Nirdesh Ojha ◽  
Florian Zeller ◽  
Claas Müller ◽  
Holger Reinecke
Keyword(s):  
Comparative Study ◽  
Material Properties ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Machining Process ◽  
Machining Parameters ◽  
Sem Images ◽  
Conductive Ceramics

Characterized by excellent material properties such has high mechanical, thermal and chemical stability technical ceramics such as ZrO2, SiC, Si3N4and AlN are increasingly being used for various applications. Traditional means of machining sintered ceramics are expensive and limited by geometry. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer (denoted as assisting electrode) on top of the non-conductive material, the EDM process can also be used to structure insulating ceramics. This paper presents a comparative study on the major machining parameters affecting the µEDM process of non-conductive SiC, ZrO2, Si3N4and AlN ceramics. The influence of five major machining parameters (current, open-circuit voltage, gap voltage, duty-cycle and servo) over two responses (material removal rate (MRR) and tool wear rate) is investigated for each ceramics material. The underlying reason for the variation in the MRR among the different ceramics is examined by comparing the material properties. Melting point of the ceramics material has an effect on the MRR for the µEDM of different ceramics. The bulk resistance value of the ceramic material does not have an influence on the MRR for the µEDM of different ceramics. Scanning electron microscope (SEM) images of the cross section of the unprocessed and µEDM processed surface of these ceramics have been analyzed. The SEM micrographs show that the µEDM process does not affect the ceramics bulk. It also confirmed spalling as one of the dominant material removal mechanism for ZrO2ceramics.

Electrical Discharge Machining Electrodes Manufactured via Selective Laser Sintering Technique Using New Composite Materials

2013 ◽  
Author(s):  
Fred Lacerda Amorim ◽  
Tiago Czelusniak ◽  
Camila Higa
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Selective Laser Sintering ◽  
Research Work ◽  
Laser Sintering ◽  
Superior Performance ◽  
Future Research ◽  
Machining Processes ◽  
Functional Components

The cost of a part manufactured by Electrical Discharge Machining (EDM) is mainly determined by electrode cost. The production of electrodes by conventional machining processes is complex, time consuming and can account for over fifty percent of the total EDM process costs. The emerging Additive Manufacturing (AM) technologies provide the possibility of direct fabrication of EDM electrodes. Selective Laser Sintering (SLS) is an alternative AM technique because it has the possibility to directly produce functional components, reducing the tool-room lead time and total EDM costs. The main difficulty of manufacturing an EDM electrode using SLS is the selection of an appropriate material, once both processes require different material properties. The current work focused on the investigation of appropriate materials that fulfill EDM and SLS process demands. Three new metal-matrix materials composed of Mo-CuNi, TiB2-CuNi and ZrB2-CuNi were developed and electrodes under adequate SLS conditions were manufactured. EDM experiments using different discharge energies were carried out and the performance evaluated in terms of material removal rate and volumetric relative wear. The results showed the powder systems composed of Mo-CuNi, TiB2-CuNi and ZrB2-CuNi revealed to be successfully processed by SLS and the EDM experiments demonstrated that the newly composite electrodes possess superior performance when compared to copper powder electrodes made with SLS. The work also suggests important topics for future research work on this field.

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.

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