Fabrication of Functional Gradient Materials Electrode and its Application in Micro-EDM

2017 ◽  
Vol 868 ◽  
pp. 151-157
Author(s):  
Xiao Peng Li ◽  
Yuan Gang Wang ◽  
Fu Ling Zhao ◽  
Meng Hua Wu
Keyword(s):  
Electrical Discharge Machining ◽  
Gradient Material ◽  
Homogeneous Material ◽  
Tool Electrode ◽  
Micro Edm ◽  
Gradient Materials ◽  
Functional Gradient ◽  
Micro Electrical Discharge Machining ◽  
Functional Gradient Material ◽  
Edm Process

The concept and the primary preparation method of functional gradient materials are described in this paper. Functional gradient material is prepared as a tool electrode by electrochemical method and its performance is further tested in the micro electrical discharge machining (micro-EDM) experiments. Compared with the homogeneous material electrode, the functional gradient material electrode can effectively inhibit the wearing of the tool electrode and improve the distribution trend of current density during the micro-EDM process. The results disclose the prospects for functional gradient material to be used as tool electrode in the micro-EDM process.

Experimental Research of Micro Reversible Electrical Discharge Machining

2009 ◽  
Vol 69-70 ◽  
pp. 177-181
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Ying Huai Dong ◽  
Hui Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Metallurgical Bonding ◽  
Machining System ◽  
Micro Structures ◽  
Edm Process

Based on the principle of micro electrical discharge machining (EDM), a reversible machining method is proposed, which can achieve depositing or removing selectively metal material for the fabrication of micro structures. It is easy to transform the machining process from deposition to removal in one machining system. The characteristics of the deposited material show that the components of deposited material are almost the same as those of the tool electrode, and the metallurgical bonding has formed on the interface between the deposited material and the base. Moreover, the deposited material has well machinability in different micro EDM selective removal process, including micro EDM die-sinking and micro EDM milling. As a result, a micro square column with 0.1mm in side length, 0.88mm in height and a micro cylinder with 0.14mm in diameter, 1.18mm in height were fabricated by using the micro reversible EDM process.

scholarly journals An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

2017 ◽  
Vol 64 (2) ◽  
pp. 149-163 ◽  
Author(s):  
Govindan Puthumana
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Micro Edm ◽  
Modeling And Analysis ◽  
Micro Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Main Effect

AbstractTo achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a regression relationship between tool wear ratio and the process inputs has been developed.

scholarly journals STRESS CONCENTRATION IN A HOMOGENEOUS PLATE WITH A CIRCULAR HOLE REINFORCED BY AN INCLUSION FROM A FUNCTIONAL-GRADIENT MATERIAL

2021 ◽  
pp. 110-115
Author(s):  
Eteri Hart ◽  
Terokhin Bohdan
Keyword(s):  
Elastic Modulus ◽  
Stress Concentration ◽  
Circular Hole ◽  
Strain State ◽  
Isotropic Plate ◽  
Gradient Material ◽  
Homogeneous Material ◽  
Functional Gradient ◽  
Homogeneous Plate ◽  
Functional Gradient Material

Computer simulation of the stress-strain state of a thin rectangular homogeneous isotropic plate with a circular hole, reinforced by an annular inclusion made of a functional-gradient material (FGM) has been carried out. The influence of the geometric (width) and mechanical (elastic modulus) parameters of the inclusion is investigated when various laws of change in the elastic modulus of the FGM are set on the stress concentration around the hole. Recommendations for the use of inclusions are given. If there is a "hard" annular inclusion in a homogeneous plate with a hole, it is expedient to use an FGM with a nonlinear law of change in the modulus of elasticity in comparison with an inclusion made of a homogeneous material. Despite the fact that the inclusion leads to a slight increase in the stress concentration factor in comparison with a homogeneous material, it makes it possible to increase the rigidity of the system as a whole. The width of FGM inclusions affects the nature of the stress distribution: the wider the inclusion, the more smoothly the stress redistribution in the main matrix occurs.

Material Removal and Fracture Detection in Micro-EDM Processes

2011 ◽  
Vol 462-463 ◽  
pp. 1092-1096 ◽  
Author(s):  
Muslim Mahardika ◽  
Gunawan Setia Prihandana ◽  
Takashi Endo ◽  
Suyitno ◽  
B. Arifvianto ◽  
...  
Keyword(s):  
Pulse Energy ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Micro Machining ◽  
Fracture Detection ◽  
Charge Voltage ◽  
Discharge Pulse ◽  
Micro Electrical Discharge Machining

The important thing in micro-machining is its accuracy. The Micro-Electrical Discharge Machining (micro-EDM) is a promising method in micro-machining, because (1) the process is independent on the hardness of the workpiece but only depends on its thermal conductivity and melting point and (2) it can be used to machine materials with highly complex geometrical shapes using a simple-shaped tool electrode. However, the process in micro-EDM is not totally well-known, especially related to the formation of discharge pulse energy and the fracture phenomena. In the micro-EDM processes, the formation of discharge pulse energy is a complex phenomenon, since it is related to many parameters such as discharge gap, charge voltage, capacitance, and tool electrode wear. In this paper, the Acoustic Emission (AE) sensor is used to detect the changes of discharge pulse energy during machining of brass using micro-EDM. The results shows that the AE signals can detect and explain the fracture phenomena during the micro-EDM processes.

P-Type and N-Type Bi2Te3/PbTe Functional Gradient Materials for Thermoelectric Power Generation

2007 ◽  
Vol 534-536 ◽  
pp. 1493-1496 ◽  
Author(s):  
Kwang Yong Lee ◽  
Tae Sung Oh
Keyword(s):  
Power Generation ◽  
Thermoelectric Power ◽  
Output Power ◽  
Hot Pressing ◽  
Gradient Material ◽  
Mechanically Alloyed ◽  
Gradient Materials ◽  
Functional Gradient ◽  
Functional Gradient Material ◽  
P Type

The p-type (Bi0.2Sb0.8)2Te3/(Pb0.7Sn0.3)Te functional gradient material (FGM) was fabricated by hot-pressing the mechanically alloyed (Bi0.2Sb0.8)2Te3 and the 0.5 at% Na2Te-doped (Pb0.7Sn0.3)Te powders. Also, the n-type Bi2(Te0.9Se0.1)3/PbTe FGM was processed by hot-pressing the mechanically alloyed Bi2(Te0.9Se0.1)3 and the 0.3 wt% Bi-doped PbTe powders. With △T larger than 300°C, the p-type (Bi0.2Sb0.8)2Te3/(Pb0.7Sn0.3)Te FGM exhibited larger thermoelectric output power than those of the (Bi0.2Sb0.8)2Te3 and the 0.5 at% Na2Te-doped (Pb0.7Sn0.3)Te alloys. For the n-type Bi2(Te0.9Se0.1)3/PbTe FGM, the thermoelectric output power superior to those of the Bi2(Te0.9Se0.1)3 and the 0.3 wt% Bi-doped PbTe was predicted at △T larger than 300°C.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Recent Patents on Micro-EDM Milling

2020 ◽  
Vol 13 (3) ◽  
pp. 219-229
Author(s):  
Baocheng Xie ◽  
Jianguo Liu ◽  
Yongqiu Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Processing Method ◽  
Electrode Wear ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Processing Methods ◽  
Machining Quality ◽  
Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

Research on Material Erosion Mechanisms of High Si-Al Alloy by Micro-EDM

2013 ◽  
Vol 652-654 ◽  
pp. 1157-1162
Author(s):  
Fu Qiang Hu ◽  
Jian Fei Sun ◽  
Jun Qi Wei ◽  
Yong Zhang ◽  
Yan Dong Jia ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Spray Forming ◽  
Copper Electrode ◽  
Al Alloy ◽  
Micro Edm ◽  
Tungsten Electrode ◽  
Micro Electrical Discharge Machining ◽  
Material Erosion ◽  
Erosion Mechanisms ◽  
Set Up

This paper researches the material erosion mechanisms of high silicon- aluminum (Si-Al) alloy in micro electrical discharge machining (Micro-EDM). By using Quanta 200F environment scanning electron microscope, the microstructure of Al-50wt%Si alloy by spray forming was observed. And a simplified model of high Si-Al alloy was set up. The Al-50wt%Si alloy was machined by using copper electrode and tungsten electrode respectively. And the differences of surface morphologies and element energy spectrum were compared. The process and the material erosion mechanisms of high Si-Al alloy in Micro-EDM were analyzed in detail. The results may provide theoretical basis for Micro-EDM of high Si-Al alloy.

The Downsizing Effects in EDM Drilling of Micro Holes

2013 ◽  
Vol 549 ◽  
pp. 503-510 ◽  
Author(s):  
Gianluca D'Urso ◽  
Giancarlo Maccarini ◽  
C. Merla
Keyword(s):  
Electrical Discharge Machining ◽  
Steel Plates ◽  
Drilling Process ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Micro Holes ◽  
Micro Drilling ◽  
Micro Features ◽  
Electron Microscopes ◽  
Manufacturing Technologies

The recent miniaturization trend in manufacturing, has enhanced the production of new and highly sophisticated systems in various industrial fields. In recent years, machining of the so called difficult to cut materials has become an important issue in several sectors. Micro Electrical Discharge Machining (micro-EDM) thanks to its contactless nature, is one of the most important technologies for the machining of this type of materials and it can be considered as one of the most promising manufacturing technologies for the fabrication of micro components. One of the most relevant applications of micro-EDM is micro-drilling. Micro holes in fact, are widely used for example in micro-electromechanical systems (MEMS), serving as channels or nozzles to connect two micro-features, and in micro-mechanical components. The present study is about micro drilling of metal plates by means of micro-EDM technology. In particular, the aim of this work is to investigate the effects of the downsizing of the micro holes diameter on the drilling performances. The influence of the reduction of the diameters in terms of both process performances (e.g., tool wear, taper rate, diametrical overcut) and general quality of the holes was investigated. Steel plates having thickness equal to 0.8 mm were taken into account. The drilling process was carried out using a micro-EDM machine Sarix SX 200 with carbide electrodes having diameter equal to 300, 200, 100 and 50 μm. Since the standard electrodes adopted in this study had a diameter equal to 300 μm, a wire EDM unit was used to obtain the other electrodes. The relationship between the process parameters considered the most significant and the final output, was studied. Furthermore, the geometrical and dimensional properties of the micro-holes were analyzed using both optical and scanning electron microscopes. In particular, it is demonstrated that the diameter size has a significant influence on the final value of the diametrical overcut while peak current and frequency parameters have a negligible effect.

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