scholarly journals Impact of orbiting electrode motion on the accuracy of electrical discharge machining

2021 ◽  
Vol 25 (5) ◽  
pp. 559-567
Author(s):  
P. V. Tatanov ◽  
A. R. Yanushkin ◽  
D. A. Schneider ◽  
A. S. Yanyushkin
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Small Diameter ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Hard Alloys ◽  
Tool Steels ◽  
Main Production ◽  
Blanking Die

The present study is designed to study processes occurring during the electrical discharge machining (EDM) of tool steels, the influence of orbiting electrode motion on its accuracy, as well as to justify the application of individual orbiting trajectories and implement these data into production. To that end, a trajectory program was written in machine codes for a Mitsubishi EA-28 die-sinking electrical discharge machine using the CIMCO EDIT software package. Also, a prototype punch and ejector of the blanking die were produced and measured. The standard modes of Mitsubishi EA-28 were used to carry out machining in Blasospark GT 250 dielectric fluid to a roughness of Ra 0.6 in 9 passes. The experiments revealed the influence of electrode geometry on the machining of sharp corners, i.e., the formation of unwanted radii on the workpiece. However, this phenomenon is not observed when the corners are drilled with small diameter holes (0.4–0.6 mm). Depending on the machining process along the inner or outer trajectory, inverse electrode motion is also observed. The production part (punch of the blanking die) was machined using a new orbit adjusted to the geometry of the product. The part was found to be consistent with the requirements and the engineering drawing, thus allowing the assembled die to enter the main production. The results of the performed tests, as well as the study of domestic and foreign experience, were used to develop recommendations on the use of individual orbits in the EDM of tool steels, hard alloys, and other hard-to-machine conductive materials. The method of orbiting motion along a particular trajectory was implemented at Cheboksary Electrical Apparatus Plant (Cheboksary).

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.

An extensive review on sustainable developments of dry and near-dry electrical discharge machining processes

2021 ◽  
pp. 1-37
Author(s):  
Sampath Boopathi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Working Fluid ◽  
Dielectric Fluid ◽  
Extensive Literature ◽  
Machining Processes ◽  
Research Activities ◽  
Dry Edm

Abstract Electrical discharge machining (EDM) is very essential unconventional electro-thermal machining process to machine the contour profile of hard materials in modern production industries. The liquid dielectric fluid has been replaced by the gas and minimum quantity of liquid mixed with gas (gas-mist) to encourage the green machining processes. The various gases and gas-mist have been used as the working fluid in dry and near-dry EDM respectively. The research-contextual, various dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques applied in various dry and near-dry EDM have been illustrated through an extensive literature survey. Future research opportunities in both dry and near-dry EDM have been summarized to promote eco-friendly EDM research activities.

Investigation on the Effect of Multi Wall Carbon Nano Tubes in Wire Electrical Discharge Machining of Hybrid Metal Matrix Composites

2014 ◽  
Vol 592-594 ◽  
pp. 456-460
Author(s):  
S. Ramesh ◽  
N. Natarajan ◽  
Vijayan Krishnaraj ◽  
K. Sathish Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Matrix Composites ◽  
Machining Performance ◽  
Carbon Nano Tubes

Wire Electrical Discharge Machining (WEDM) is an very accurate non-traditional machining process for producing parts with accurate dimensions and complex shapes. The performance of WEDM is measured by evaluating the parameters like Material Removal Rate (MRR), Surface Roughness (Ra), cracks, voids, pores and recast layer. In this paper, an attempt is made to improve the machining performance by adding multi wall carbon nanotube (MWCNT) with dielectric fluid. The MRR, Ra and surface characteristics are compared with surface that is machined using dielectric fluid with and without MWCNT. The results show that addition of MWCNT improves the MRR and surface finish.

scholarly journals Electrical Discharge Machining: Vital to Manufacturing Industries

2019 ◽  
Vol 8 (11) ◽  
pp. 1696-1701 ◽  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Manufacturing Industries ◽  
Potential Difference ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Conventional Process ◽  
Edm Process ◽  
State Of Art ◽  
Process Material

This paper presents an insight of state of art of electrical discharge machining process. In this process, material gets eroded from the workpiece because of chain of speedily repeating current discharges amidst twin electrodes, which are parted by dielectric fluid and made prone to a potential difference. This process offers various advantages over conventional process and finds wide applications in various industries. The information provided in this study will be very useful for the beginners to understand the basic fundamentals of unconventional EDM process

scholarly journals Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2533
Author(s):  
Rakesh Chaudhari ◽  
Jay Vora ◽  
L.N.López de Lacalle ◽  
Sakshum Khanna ◽  
Vivek K. Patel ◽  
...  
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Nano Graphene ◽  
Pulse On Time ◽  
Pulse Off Time

In the current scenario of manufacturing competitiveness, it is a requirement that new technologies are implemented in order to overcome the challenges of achieving component accuracy, high quality, acceptable surface finish, an increase in the production rate, and enhanced product life with a reduced environmental impact. Along with these conventional challenges, the machining of newly developed smart materials, such as shape memory alloys, also require inputs of intelligent machining strategies. Wire electrical discharge machining (WEDM) is one of the non-traditional machining methods which is independent of the mechanical properties of the work sample and is best suited for machining nitinol shape memory alloys. Nano powder-mixed dielectric fluid for the WEDM process is one of the ways of improving the process capabilities. In the current study, Taguchi’s L16 orthogonal array was implemented to perform the experiments. Current, pulse-on time, pulse-off time, and nano-graphene powder concentration were selected as input process parameters, with material removal rate (MRR) and surface roughness (SR) as output machining characteristics for investigations. The heat transfer search (HTS) algorithm was implemented for obtaining optimal combinations of input parameters for MRR and SR. Single objective optimization showed a maximum MRR of 1.55 mm3/s, and minimum SR of 2.68 µm. The Pareto curve was generated which gives the optimal non-dominant solutions.

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.

Roughness of Small Diameter External Cylindrical Surfaces Obtained by Ram Electrical Discharge Machining

2015 ◽  
Vol 809-810 ◽  
pp. 411-416 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Ciprian Mircescu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Small Diameter ◽  
Machining Process ◽  
Surface Generation ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

In order to obtain small diameter external surfaces by ram electrical discharge machining from plate workpieces, tubular tool electrodes could be used. In such a case, one can appreciate that the obtained surface is a simple concatenation of cavities appeared as a consequence of electrical discharges developed between the asperities existing initially on the active surface of the tool electrode and surface to be machined of the workpiece. The analysis of the surface generation as a consequence of the electrical discharge machining process showed that due to the surface tensions, a leveling phenomenon could be taken into consideration. An experimental study of influence exerted by some input factors on the surface roughness parameter Ra was designed and achieved. One noticed that the increase of the pulse on time, pulse off time and peak current intensity determines an increase of the surface roughness parameter Ra. By mathematical processing of the experimental results, an empirical model type power function was determined. The examination of the machined surface by means of an optical microscope showed the existence of microcavities generated by the electrical discharge, while the material melted and re-solidified was placed as a bordure of the microcavities.

Recent Developments in Wire Electrical Discharge Machining

2019 ◽  
pp. 125-152
Author(s):  
Nadeem Faisal ◽  
Sumit Bhowmik ◽  
Kaushik Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
High Strength ◽  
Optimization Methods ◽  
Machining Process ◽  
Machining Processes ◽  
Accuracy And Precision ◽  
Recent Developments ◽  
Conventional Machining

The tremendous growth of manufacturing industries and desired need of accuracy and precision has put a great importance on non-traditional machining processes. Metal and non-metals having properties like high strength, toughness, and hardness is generally machined by non-conventional machining methods. One of earliest non-traditional machining that is still in use and being effectively utilized in industries is wire electrical discharge machine. This machining technique gives a tough line of competition to conventional machining process like milling, grinding, broaching, etc. Cutting intricate and delicate shapes with accuracy and precision gives this machining technique an edge over other conventional machining and non-conventional machining processes. This chapter provides an insight to various research and prominent work done in field of WEDM by various scientists, researchers, and academicians. The chapter also emphasizes various advantages and disadvantages of different modelling and optimization methods used. The chapter concludes with some recommendations about trends for future WEDM researchers.

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