scholarly journals Formation and Optimization of Electrical Discharge Coatings Using Conventional Electrodes

Energies ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5691
Author(s):  
JagadeeswaraRao Maddu ◽  
Buschaiah Karrolla ◽  
Srikanth Vuppala ◽  
Riyaaz Uddien Shaik
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Titanium Substrate ◽  
Dielectric Medium ◽  
Optimization Techniques ◽  
Functional Coatings ◽  
Discharge Machine ◽  
Angle Method

An emerging topic is electrical discharge (ED) coating with its application on complex shapes and cavities to repair components or act as functional coatings. Because it is a variant process of an electric discharge machine (EDM) with the ability to coat on electrically conductive substrates, there is a possibility that next-generation electrical discharge machining components may exploit the attachment phenomenon to enhance recast layer properties. Previously, researchers have obtained ED coating by mixing the powder in a dielectric medium and/or by using powder metallurgy electrodes. In this work, primarily, an insight in the formation of ED coating on-die sinks electrical discharge machine, using conventional electrode materials viz., bronze on titanium alloy (Ti-6Al-4V) is made. The bronze electrode on the titanium substrate obtained a crack-free copper coating of ~20 microns thickness. In order to perform the experiments, three combinations were made using five parameters: current (Amps), ton (µs), Toff (µs), duty cycle (%), and flushing pressure as constant (bar). After obtaining the coating, a combination of input parameters was selected by optimizing the output performance parameters, viz., the electrical discharge deposition rate, coating thickness, micro-cracks, and elemental coating composition. Secondarily, different optimization techniques viz., grey relational analysis, the technique for order of preferences by similarity to ideal solution, −nD angle method and information divergence method were implemented to find out the suitable combination of parameters where the latter two methods were introduced for the first time in this area of EDM optimization. A study was conducted to check whether the latter two methods are optimization techniques or multi-criteria decision-making techniques. The optimization of existing reactor types and the development of new reactors in wastewater treatment through EDC, by which energy could be saved by replacing the conventional techniques.

Design and Experimental Investigation on High Efficient Horizontal Micro Electrical Discharge Machine

2013 ◽  
Vol 456 ◽  
pp. 32-37
Author(s):  
Xia Yun Shu ◽  
Hong Hai Zhang
Keyword(s):  
Electric Discharge ◽  
Electrical Discharge ◽  
Influence Factor ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Examination System ◽  
Micro Electrical Discharge Machining ◽  
Grinding Method ◽  
High Efficient ◽  
Discharge Machine

Micro-electrical discharge machining is a non-contact manufacturing process without macroscopic force. Microelectrode fabrication is the fundamental and influence factor of micro electric discharge machining. As for the efficiency of microelectrode fabrication, this paper proposed a fast online microelectrode fabrication method by an efficient horizontal micro electric discharge machine, in which an online diamond wheel ultra-precision grinding method and an online wire electrical discharge grinding method is combined to fabricate microelectrode. Machine designed in this paper consist of a CCD online dimension examination system, precision motion and feeding system, nanosecond-pulse independent discharged power supply and gap state-detection system. experimental study on microelectrode, micro nozzle fabrication and microstructure milling by the machine conducted. Microelectrode with 15 micrometers in diameter and micro hole with 50 micrometers in diameter are done in experiment. Results show that the composite method improves the efficiency of micro electrical discharge machining.

scholarly journals Rekayasa Elektroda Electrical Discharge Machine Dari Bahan Baku Serbuk Tembaga Dengan Proses Kompaksi

2018 ◽  
Vol 13 (3) ◽  
pp. 91
Author(s):  
Abdul Syukur Alfauzi ◽  
Adhy Purnomo ◽  
Hariyanto Hariyanto ◽  
Nur Saada ◽  
Bambang Tjahjono
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Discharge Machine

<p><em>Electrical Discharge Machining </em><em>(EDM) adalah proses pembuangan material yang dikerjakan oleh sejumlah loncatan bunga api listrik yang terjadi pada celah antara pahat (elektroda). </em><em>Pembuatan elektroda EDM salah satunya dibuat  dengan proses metalurgi serbuk</em><em> (penekanan dan sintering) dari bahan serbuk</em><em> tembaga. Metalurgi serbuk adalah proses penekanan terhadap serbuk agar serbuk dapat men</em><em>yatu</em><em> satu dengan lainnya sebelum ditingkatkan ikatannya dengan proses sintering. Pembuatan serbuk tembaga dapat dilakukan dengan proses pengendapan elektrolisis (electrorefining). Serbuk tembaga kemudian dilakukan proses kompaksi, sintering dan uji kekerasan untuk menghasilkan elektroda EDM yang optimal. Dengan mesin cetak menggunakan tenaga hidrolik yang berkemampuan tekan 6 ton, dapat mencetak bentuk elektroda EDM yang terbaik pada tekanan (P) sebesar 8,8 (MPa), gaya (F) sebesar 60 (kN) dilanjutkan dengan proses sintering dengan temperatur 900<sup>0</sup>C dan waktu penahanan 1 jam sehingga menghasilkan produk dengan nilai kekerasan 77 (kg/mm<sup>2</sup>)<strong>.</strong></em><em> </em></p><strong></strong><em></em>

Elementary Study on the Creation of Cross Section's Changing Holes by Means of Electrical Discharge Machining

2009 ◽  
Vol 3 (5) ◽  
pp. 592-601 ◽  
Author(s):  
Tohru Ishida ◽  
◽  
Yuichi Mochizuki ◽  
Yoshimi Takeuchi ◽  
Keyword(s):  
Cross Sections ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
New Method ◽  
Mechanical Parts ◽  
Translational Movement ◽  
Discharge Machine ◽  
The Creation ◽  
Inside Wall

This study deals with the development of a new method to machine holes whose cross sections variously change along their axes. Machined holes have straight axes and constant circular cross sections, since holes are generally machined by drills. In other words, the shapes of machined holes do not have much variety. This study, however, develops a new, elementary device which can machine a certain shape on the inside wall of a straight hole by means of electrical discharge machining. This results in the creation of holes with variously changing cross sections. The aforementioned device consists of an electrode for electrical discharge machining and some mechanical parts, and is installed on a die-sinking electrical discharge machine (EDM). The device and EDM operate as a reciprocating block slider crank mechanism, so a translational movement of the main axis of the EDM can be converted into a rotational movement of the electrode. As a result, shapes which are identical to the envelope of the locus of the electrode movement can be machined. This leads to the creation of a semicircular space on the inside wall of a straight hole by starting the machining after setting the electrode in the hole. Experimental results show that, by changing the shape of the electrode, the device can produce variously shaped, semicircular spaces inside a straight hole. This proves that the new method of machining has the ability to create holes which have complicatedly changing cross sections.

scholarly journals Optimization of Process Parameter by using CNC Wire Electrical Discharge Machine through Taguchi Method

2020 ◽  
Vol 9 (6) ◽  
pp. 518-522
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Wire ◽  
Electrical Discharge Machine ◽  
Research Work ◽  
Process Parameter ◽  
Machining Speed ◽  
Discharge Machine

Wire Electrical Discharge Machining (WEPSPDM) is utilizedin industries to manufacture components of conductive strong metal with complicated shape, greater tolerance and precision. A review of the literature exposes that most of the research work has been intended for towards the optimization of WEDM operation and modeling of the process. Conventional wire electrode has been developed to a brass wire from a copper wire and finally to zinc coated wire on the brass, steel or copper wire core, by which more advanced WEDM, is realized in terms of better machining speed and accuracy. To examine the parameters likePeak Current (Ip ), Time of Pulse ON (Ton), Time of Pulse OFF (Toff), etc. by the optimization of WEDM operation and modeling of the process during micro slit machining. Analyzed the results and optimize the process parameter conditions for maximum MRR (g/min), and surface roughness based on Taguchi’s Methodology. The ANOVA analysis indicates the significant factors for maximization of MRR, improvement of Surface Roughness and regression analysis. By the research work, it has been concluded that the MRR reduces with raise in Time of Pulse OFF (Toff) and Set Voltage of spark gap (SV) besides Material Removal Rate (MRR) increases with escalating in Time of Pulse ON (Ton) and PC (IP).

scholarly journals Optimization of the Electrical Discharge Machine using AZ 31 Magnesium alloy

2019 ◽  
Vol 8 (3) ◽  
pp. 5790-5794
Keyword(s):  
Magnesium Alloy ◽  
Electrical Discharge ◽  
Complex Structure ◽  
Electrical Discharge Machine ◽  
Optimization Techniques ◽  
Electrode Wear ◽  
Discharge Machine ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Electrical Discharge Machine (EDM) is the process of designing the material and including complex structure using electrical discharge. Many research has been carried out in the EDM using different materials to increase Material Removal Rate (MRR), decrease Electrode Wear Rate (EWR) and Surface Roughness (SR). The various optimization techniques are applied to identify the parameter settings to increase MRR. In this research, the EDM process is conducted using the material of AZ 31 Magnesium alloy with hydrothermal treatment to reduce the MRR. The Taguchi method is applied to identify the optimal parameter for the EDM process to minimize the MRR, EWR and SR. The optimal value of the method is obtained as peak current of 55 A, voltage of 220 V, pulse on-time of 16 µs, and the pulse off-time of 512 µs.

Creation of U-Shaped and Skewed Holes by Means of Electrical Discharge Machining Using an Improved Electrode Curved Motion Generator

2008 ◽  
Vol 2 (6) ◽  
pp. 439-446 ◽  
Author(s):  
Tohru Ishida ◽  
◽  
Yoshimi Takeuchi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Water Channels ◽  
Mechanical Parts ◽  
Smooth Flow ◽  
Curved Hole ◽  
Discharge Machine ◽  
Low Efficiency ◽  
Conventional Machining

This study deals with the development of a new method of machining curved holes for water channels built in molds, holes which cannot be fabricated using current machining methods in practical use. Since holes are generally formed by drilling, water channels are a series of straight holes. This causes obstructions to the smooth flow of the coolant, leading to low efficiency and unstable performance in the cooling of the molds. To solve these problems, the authors have developed new devices that can machine curved holes, thus enhancing the degree of freedom of water channels. An earlier device consisted of simple mechanical parts installed on a die-sinking electrical discharge machine (EDM). It was able to fabricate an L-shaped curved hole. However, the controllability of the shape of the curved holes it produced was unfortunately low. To overcome this weakness, the device has been improved and now it can machine curved holes of a variety of shapes. Through application experiments, it has been found that U-shaped and skewed holes, holes which cannot be produced using conventional machining methods, can also be created employing the improved device.

Device for Wire Electrical Discharge Machining

2014 ◽  
Vol 657 ◽  
pp. 569-573
Author(s):  
Gheorghe Bosoancă ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Ana Bădănac ◽  
Vasile Manole
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Tool Electrode ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrical Discharge Machine ◽  
Machining Processes ◽  
Discharge Machine ◽  
The Wire ◽  
The Given

The problem approached in this paper refers to designing a device for wire electrical discharge machining (EDM) which can be used on a ram electrical discharge machine. Usually, wire electrical discharge machine is applied only on specialized electrical discharge machines. The device proposed in the paper will ensure widening the technological possibilities of the given ram EDM equipment. A principle schema of the device was established, after analyzing the main requirements specific to the device service. One took into consideration a possibility to rotate and fix the subassembly for guiding the wire electrode so that the active zone of the wire tool electrode has a horizontal, vertical or even inclined position. Another requirement was to ensure a way for achieving machining processes in cavities existing in workpieces of higher dimensions. Functioning of the designed device and strain resistance of some components were tested by using CATIA V5 software. Some optimization possibilities for this constructive solution of the device were identified.

Programming for Machining in Electrical Discharge Machine

2021 ◽  
pp. 55-75
Author(s):  
Chikesh Ranjan ◽  
Hridayjit Kalita ◽  
T. Vishnu Vardhan ◽  
Kaushik Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Correct Selection ◽  
Hard Material ◽  
Heat Treated ◽  
Mold Making ◽  
Discharge Machine ◽  
Heat Resistant Steels ◽  
Die And Mold

The correct selection of manufacturing conditions is one of the most important aspects to take into consideration in most manufacturing processes and, particularly, in processes related to electrical discharge machining (EDM). It is a capable of machining geometrically complex or hard material components that are precise and difficult-to-machine such as heat-treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels, etc. being widely used in die and mold making industries, aerospace, aeronautics, and nuclear industries. This chapter highlights the programming for machining in electrical discharge machine.

scholarly journals A review on the effect of using rotary hyflex electrical discharge machining endodontic files on the formation of dentinal microcracks in straight root canals

2021 ◽  
Vol 12 (4) ◽  
pp. 63-65
Author(s):  
Yasir Al-Hashimi ◽  
Ahmed Abyad ◽  
Ahmed Abyad ◽  
Yasir Al-Hashimi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Micro Ct ◽  
New Era ◽  
Root Canals ◽  
Micro Cracks ◽  
Before And After ◽  
Unique Shape ◽  
Discharge Machine

Endodontic therapy is based on cleaning and shaping the canal system till the apex with total obturation of the canal. However, it is not always straightforward. Endodontics specialists face many complicated cases as sever curved canals, calcified canals and canals with previously initiated therapy which require to deal with. dental professionals pay attention to create new methods or to improve the already developed equipment and procedures to facilitate their work. Rotary endodontics files are in the center of attention. nowadays, recent files with extraordinary properties have been revolutionized. The standard Nickel Titanium rotary endodontic files are not always preferred. It cannot serve well in the aforementioned complex cases due to its larger tapers and unique shape memory property. Moreover, these files have led to several dentinal microcracks formation during canal preparation using the flaring instruments. Microcracks are evaluated through the accurately presented sliced images using Micro-Computer Tomography (micro-CT) done before and after root canal preparation. This has led to the invention of new generations of rotary endodontics files, with unique properties improving its behavior during the instrumentation, including Controlled Memory (CM) files and Electrical discharge Machine (EDM) files, opening the door for a new era in the field of endodontics dentistry. The present study aims to review HyFlex EDM files, including their properties, clinical dental usage, and the role of micro-CT in analyzing dentinal micro cracks formed with HyFlex EDM files.

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