scholarly journals Micro-EDM Machining With Copper Foil

2021 ◽  
Author(s):  
Katerina Mouralova ◽  
Josef Bednar ◽  
Libor Benes ◽  
Tomas Prokes ◽  
Jiri Fries
Keyword(s):  
Copper Foil ◽  
Pulse Current ◽  
Micro Edm ◽  
Clear Trend ◽  
Electrically Conductive ◽  
Surface Design ◽  
Optical Instruments ◽  
Micro Parts ◽  
Optimal Setting ◽  
Pulse On Time

Abstract Electrical discharge die-sinking machining (EDM) is one of the indispensable unconventional technologies enabling the machining of all materials that are at least minimally electrically conductive. Due to the clear trend of miniaturization of products, it is necessary to ensure their quality and accurate production, also with the help of micro-EDM. It is the optical instruments used for testing car lights that contain these miniaturized parts necessary for the correct functioning of the device. For this reason, this study was performed, which focused on the production of a precise slot measuring 5000x170 µm in a copper foil with a thickness of 125 µm. The same copper foil was used as a tool, which represents an advance in the production of micro-parts. A design of experiment Box and Behnken Response Surface Design was performed for a total of 15 rounds, monitoring the effect of machine setting parameters (Pulse current, Pulse on time and Voltage) on responses in the form of Erosion rate, corner radius, slot length and width. Using multi-criteria optimization, the optimal setting of the machine parameters for the production of a given slit was determined, which is Pulse current = 2.1 A, Pulse on time = 40 µs and Voltage = 238.8 V.

Monitoring of EDM parameters to develop tribo-adaptive Ti6Al4V surfaces through accretion of alloyed matrix

2019 ◽  
Vol 72 (3) ◽  
pp. 291-297
Author(s):  
Jibin T. Philip ◽  
Deepak Kumar ◽  
S.N. Joshi ◽  
Jose Mathew ◽  
Basil Kuriachen
Keyword(s):  
Electrical Discharge Machining ◽  
Tribological Behavior ◽  
Wear Behavior ◽  
Removal Rate ◽  
Advanced Materials ◽  
Surface Alloying ◽  
Electrically Conductive ◽  
Content Type ◽  
Pulse On Time

Purpose Electrical discharge machining (EDM) is well-known for its credibility in the processing of advanced materials, which are electrically conductive. The strenuous effort associated with machining of Ti6Al4V (Ti64) using conventional methods, and its low tribological behavior, present an immediate need to develop solutions to monitor and improve the compatible techniques such as EDM. Design/methodology/approach The present work includes following: monitoring the ED process parameters, namely, current (I) and pulse on time (Ton), in controlling the material removal rate and surface roughness (Ra and Sa) for development of tribo-adaptive surfaces; and investigation on the role of oxides pertinent to the tribo-behavior of Ti64 (bare and EDMed) surfaces. Findings The tribological behavior of Ti6Al4V surfaces got remarkably improved through ED machining, which points to the credibility of the process to establish itself as a surface alloying technique. The recast layer (RL, alloyed matrix) acted as a protective coating; stable enough to assist the developed tribo-oxides such as TiO and Ti8O15 in rendering improved sliding performance at load = 50 N and speed = 0.838 ms−1. Originality/value The surface modification through ED machining was experimentally proven to improve the wear behavior of Ti6Al4V surfaces.

Fabrication of Tapered Micro Pillars on Titanium Using Electric Discharge Micromachining

2014 ◽  
Author(s):  
V. K. Jain ◽  
Vishnu Suthar ◽  
Anjali V. Kulkarni
Keyword(s):  
Titanium Alloy ◽  
Removal Rate ◽  
Statistical Technique ◽  
Surgical Instruments ◽  
Work Piece ◽  
Chemical Plants ◽  
Electrically Conductive ◽  
Taper Angle ◽  
Micro Pillars ◽  
Pulse On Time

Materials are made harder, tougher, heat resistant and more corrosion resistant which make them difficult-to-machine by traditional machining methods. Titanium and its alloys are in the group of these difficult-to-machine materials, and these alloys have applications in aerospace, power generation, surgical instruments, automobile, chemical plants etc. Ti-6Al-4V is amongst the commonly used titanium alloy, and the current research is focused on its efficient machining. Electro discharge micromachining can be used for producing features in micro range on electrically conductive materials. Straight micro electrodes have been produced using EDMM process. The main objective of the current research is to achieve array of tapered micro pillars on Ti-6Al-4V Work piece material using EDMM process. The effect of process parameters such as gap voltage, discharge current, pulse on-time and duty cycle on the response parameters such as taper angle, material removal rate (MRR) and tool wear rate (TWR) are studied. The experiments are designed using statistical technique. After studying the results of the experiments, the array of micro tapered pillars of different taper angles is produced to see the feasibility of fabrication of tapered pillars on titanium alloy using EDMM process.

Modeling of Recast Layer in Micro-Electrical Discharge Machining

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
P. C. Tan ◽  
S. H. Yeo
Keyword(s):  
Numerical Model ◽  
Electrical Discharge ◽  
Prediction Models ◽  
Electrical Discharge Machining ◽  
Performance Measure ◽  
Recast Layer ◽  
Micro Edm ◽  
Machined Surface ◽  
Functional Layer ◽  
Pulse On Time

The thickness of recast layers produced during electrical discharge machining (EDM) is an important process performance measure as it may indicate an extent of crack propagation in a machined surface or thickness of a functional layer alloyed onto a machined surface. Thus, the availability of the recast layer thickness prediction models is needed to allow better control of machining outcomes, which becomes more vital for micro-EDM due to the microscale of machined features. The proposed numerical model, based on a multiple discharge approach for recast layer prediction, is developed to fill an existing gap in micro-EDM. The multiple discharge approach accounts for the overlapping nature by which craters are generated on the machined surface and considers the recast layer to be a combination of individual recast regions from individual craters. The numerical analysis, based on finite element methods, is used to determine the melting isotherms due to heat inputs on overlapping crater profiles. Then, a hemispherical-capped crater profile is estimated by applying a recast plasma flushing efficiency to the amount of molten material bounded by the melting isotherm. Finally, the recast region is defined to be bounded by the melting isotherm and crater profile. The model, developed for a peak discharge current of 1.45 A and pulse on time between 166 ns and 606 ns, predicted recast layer thicknesses of between 1.0 μm and 1.82 μm. It is then validated at pulse on time settings of 244 ns and 458 ns, which generated average recast layer thicknesses of 1.18 μm and 1.56 μm, respectively. Thus, the numerical model developed using the multiple discharge approach is suitable for estimation of recast layer thicknesses in micro-EDM.

Response Surface Analysis of EDMED Surfaces of AISI D2 Steel

2011 ◽  
Vol 264-265 ◽  
pp. 1960-1965
Author(s):  
Mohan Kumar Pradhan ◽  
Chandan Kumar Biswas
Keyword(s):  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Machining Parameters ◽  
Response Functions ◽  
Process Variables ◽  
Aisi D2 ◽  
Pulse On Time ◽  
D2 Steel ◽  
Machining Characteristics

In this study, the effects of the machining parameters in electrical-discharge machining (EDM) on the machining characteristics of AISI D2 steel using copper electrodes were investigated. The response functions considered material removal rate (MRR) and Surface Roughness (Ra),while machining variables are pulse current, pulse on time, pause time and gap voltage. A Response surface methodology was used to reduce the total number of experiments. Empirical models correlating process variables and their interactions with the said response functions have been established. The significant parameters that critically influenced the machining characteristics were examined, and the optimal combination levels of machining parameters for material removal rate, and surface roughness were determined. The models developed reveal that pulse current is the most significant machining parameter on the response functions followed by voltage and pulse off time for MRR. However for, for Ra also pulse current is most significant followed by pulse on time and discharge voltage the respectively. The model sufficiency is very satisfactory as the coefficientR2of is determination (R2) is found to these be greater than 98 %. These models can be used for selecting the values of process variables to get the desired

ELECTRICAL DISCHARGE MACHINING OF Al/7.5% Al2O3 MMCs USING ROTARY TOOL AND Al2O3 POWDER

2017 ◽  
Vol 24 (02) ◽  
pp. 1750018 ◽  
Author(s):  
SAEED DANESHMAND ◽  
BEHNAM MASOUDI ◽  
VAHID MONFARED
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Pulse On Time

Nowadays, composites are used in different parts of industries and it is one of the most important subjects. The most widely used reinforcements in metal matrix composites are Al2O3 and SiC fibers and particles which may be used in cutting-edge functional and structural applications of aerospace, defense, and automobile industries. Depending on the type of powder used, composite materials are difficult to machine by conventional cutting tools and methods. The most appropriate way for machining of these composites is electro discharge. For the reason of improving the surface quality, tool wear rate and material removal rate and reducing the cracks on the surface, Al2O3 powder was used. In this study, the effect of input parameters of EDM such as voltage, pulse current, pulse on-time and pulse off-time on output parameters like material removal rate, tool wear rate and surface roughness in both conditions of the rotary tool with powder mixed dielectric EDM and the stationary tool excluding powder mixed dielectric were investigated. The critical parameters were identified by variance analysis, while the optimum machining parameter settings were achieved via Taguchi method. Results show that using of powder mixed dielectric and rotary tool reduce the tool wear rate, surface roughness and the cracks on the surface significantly. It is found also that using of powder mixed dielectric and rotary tool improve the material removal rate due to improved flushing action and sparking efficiency. The analysis of variance showed that the pulse current and pulse on-time affected highly the MRR, TWR, surface roughness and surface cracks.

Influence of Electrode Cooling on Material Migration among the Electrodes during EDM of Titanium Alloy

2011 ◽  
Vol 264-265 ◽  
pp. 1199-1204 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Liquid Nitrogen ◽  
Electrical Discharge Machining ◽  
Electrically Conductive ◽  
Workpiece Surface ◽  
Hard Metals ◽  
Material Migration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Dies And Moulds

Electrical discharge machining (EDM) is widely used in the machining of electrically conductive hard metals for the production of dies and moulds. This paper describes an investigation of the effect of electrode cooling on the amount of elements migration from the electrode to the workpiece surface and from the workpiece to the electrode surface. In the present study EDM has been performed with electrodes cooled by liquid nitrogen as well as with electrodes without cooling. Current, pulse-on time, pulse-off time and voltage were taken as the variables during conducting the experiments. The analysis on material migration during EDM was carried out by SEM and EDX. It was observed that EDM with liquid nitrogen reduces material migration and minimizes the surface contamination of both the electrodes.

Some Aspects of Micro-Fabrication Using Electro Discharge Deposition Process

2012 ◽  
Author(s):  
V. K. Jain ◽  
S. Seshank ◽  
Ajay Sidpara ◽  
Himanshu Jain
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Deposition Process ◽  
Substrate Material ◽  
Metallic Substrate ◽  
Operating Parameters ◽  
Micro Fabrication ◽  
Micro Parts ◽  
Micro Tool ◽  
Pulse On Time

The growing demand for micro-parts has led to the development of many processes for their production. One of the emerging processes in this category is the electric discharge deposition process in which a micro tool in the form of a wire is used. The tool wear is increased intentionally so that the worn out material gets deposited on the substrate. Experiments are designed using response surface methodology to identify the key operating parameters (voltage, current, duty cycle and pulse on-time) and then to study their effects on the structure’s height, and width. As a concluding part, micro parts (star and letters IITK) are fabricated on the substrate material and a method is proposed and demonstrated to detach micro parts from the metallic substrate material.

scholarly journals Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (3A) ◽  
pp. 319-324
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that the model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected by HAZ with 67.219% contribution.

Electrically conductive and anti-corrosive coating on copper foil assisted by polymer-nanocomposites embedded with graphene

2019 ◽  
Vol 476 ◽  
pp. 123-127 ◽  
Author(s):  
Han Kim ◽  
Hyemin Lee ◽  
Hyo-Ryoung Lim ◽  
Hong-Baek Cho ◽  
Yong-Ho Choa
Keyword(s):  
Polymer Nanocomposites ◽  
Copper Foil ◽  
Electrically Conductive

scholarly journals WEDM Used for Machining High Entropy Alloys

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4823
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Radim Zahradnicek ◽  
Josef Bednar ◽  
Antonin Zadera ◽  
...  
Keyword(s):  
Surface Quality ◽  
Machining Process ◽  
Tool Geometry ◽  
Composition Analysis ◽  
Efficient Production ◽  
High Entropy Alloys ◽  
High Entropy ◽  
Optimal Setting ◽  
Pulse On Time ◽  
Pulse Off Time

Unconventional wire electrical discharge machining technology (WEDM) is a key machining process, especially for machining newly emerging materials, as there are almost no restrictions (only at least minimal electrical conductivity) in terms of demands on the mechanical properties of the workpiece or the need to develop new tool geometry. This study is the first to present an analysis of the machinability of newly developed high entropy alloys (HEAs), namely FeCoCrMnNi and FeCoCrMnNiC0.2, using WEDM. The aim of this study was to find the optimal setting of machine parameters for the efficient production of parts with the required surface quality without defects. For this reason, an extensive design of experiments consisting of 66 rounds was performed, which took into account the influence of five input factors in the form of pulse off time, gap voltage, discharge current, pulse on time, and wire speed on cutting speed and the quality of the machined surface and its subsurface layer. The analysis of topography, morphology, subsurface layers, chemical composition analysis (EDX), and lamella analysis using a transmission electron microscope (TEM) were performed. An optimal setting of the machine parameters was found, which enables machining of FeCoCrMnNi and FeCoCrMnNiC0.2 with the required surface quality without defects.

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