An Investigation of Attachment on Electrode Surface in Dry EDM

2010 ◽  
Vol 126-128 ◽  
pp. 407-412 ◽  
Author(s):  
Ke Yu Shue ◽  
Yao Yang Tsai ◽  
Yo Ming Chang
Keyword(s):  
Electrode Surface ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Work Piece ◽  
Electrode Wear ◽  
High Discharge ◽  
Peak Current ◽  
Dry Edm ◽  
Discharge Ratio ◽  
Melting Material

Dry Electrical discharge machining (Dry EDM), using gas as dielectric, has been developed to solve problems against environment. It has both advantages of high material removal ratio (MRR) and low relative electrode wear ratio (REWR). We investigated the effect of duty factor, peak current, and reference ratio of gap voltage on MRR and REWR of Dry EDM, respectively. Moreover, trying to prove the attachment on electrode surface could decline REWR. It is considered that melting material of work-piece was sputtered and stuck onto electrode surface, and to become a protection layer as result in low REWR. However, the attachment will be removed under the condition of high peak current and high discharge frequency. But the amount of attachment just has little change when discharge number and arc discharge ratio are both decrease.

Effect of Higher Peak Current and Pulse Duration on EWR of Copper Electrode when Electrical Discharge Machining (EDM) of Inconel 718

2013 ◽  
Vol 845 ◽  
pp. 945-949
Author(s):  
S. Ahmad ◽  
Mohd Amri Lajis
Keyword(s):  
Wear Rate ◽  
Pulse Duration ◽  
Electrode Surface ◽  
Inconel 718 ◽  
Copper Electrode ◽  
Work Piece ◽  
Electrode Wear ◽  
Peak Current ◽  
Electrode Wear Rate ◽  
Pulse On Time

In this work, the electrode wear rate (EWR) and electrode surface characteristic of copper electrode when EDM of Nickel Based Super Alloy, Inconel 718 at higher peak current and pulse duration were analyzed. Experiments were conducted using Inconel 718 as a work piece and copper as an electrode with a kerosene dielectric under different peak currents and pulse durations. Peak current, Ip within a range of 20A to 40A and pulse duration (or pulse on-time), ton within a range of 200μs to 400μs are selected as the main parameters. In this study, EWR were measured using digital weight balance (accuracy 0.01mg) and by using Scanning Electron Microscope (SEM), the surface texture of the electrode in order to evaluate the material deposited on the electrode surface. The results have shown that machining at a lowest peak current of 20A and highest pulse duration of 400μs yields the lowest electrode wear rate (EWR) of -0.01mm3/min. The pulse duration is significantly affecting the EWR. It also revealed that, the deposited of carbon and work piece material is occurred on the electrode surface for all machining conditions.

Effect of Arc Discharge Pressure on Discharge Current in EDM

2008 ◽  
Vol 381-382 ◽  
pp. 451-454
Author(s):  
Atsutoshi Hirao ◽  
S. Tai ◽  
H. Takezawa ◽  
Naotake Mohri ◽  
Kazuro Kageyama ◽  
...  
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Vibration Sensor ◽  
Work Piece ◽  
Tool Electrode ◽  
Discharge Pressure ◽  
Current Behavior

In electrical discharge machining (EDM), an electrical discharge occurs between a tool electrode and a work-piece, and removal of materials is carried out by vaporized explosion between the electrode and the work-piece. However, the mechanism of material removal in EDM is not well understood. In order to clarify this issue, the acoustic emission (AE) method has been applied to examine the force of explosion, and the Schlieren visualization method has been applied to observe the explosion. In this study, we investigate the effect of discharge current behavior on the occurrence of the AE waves by means of an optical fiber vibration sensor.

High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

scholarly journals Comparative Analysis of Dry-EDM and Conventional EDM in machining of Hastelloy

2021 ◽  
Vol 12 (3) ◽  
pp. 3538-3543
Author(s):  
Apurva A Kulkarni Et.al
Keyword(s):  
High Velocity ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Dielectric Medium ◽  
Work Piece ◽  
Tool Electrode ◽  
Dry Edm ◽  
Discharge Gap ◽  
Edm Process

Dry EDM may be a modification of the traditional electrical discharge machining (EDM) process during which the liquid dielectric is replaced by a gaseous medium. High velocity gas is supplied through it into the discharge gap. The flow of high velocity gas into the gap facilitates removal of debris and prevents excessive heating of the tool and work piece at the discharge spots. it's now known that aside from being an environment–friendly process, other advantages of the dry EDM process are low tool wear, lower discharge gap, lower residual stresses, smaller white layer and smaller heat affected zone.[1] Keeping literature review into consideration, during this research, an effort has been made by selecting compressed gas as a dielectric medium, with Hastelloy as a work piece material and copper as a tool electrode. Conventional experiments were also performed. Experiments are performed using Taguchi DoE orthogonal array to watch and analysis the consequences of various process parameters to optimize the response variables like material removal rate (MRR) and gear wear rate (TWR).

scholarly journals Electrical Discharge Drilling of Metal Matrix Composites with a Hollow Hexagonal Electrode

2018 ◽  
Vol 27 (5) ◽  
pp. 096369351802700 ◽  
Author(s):  
Zhibiao Lin ◽  
Zhongning Guo ◽  
Shuzhen Jiang ◽  
Guixian Liu ◽  
Jiangwen Liu
Keyword(s):  
Duty Cycle ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Rotation Speed ◽  
Aluminum Matrix ◽  
Aluminum Matrix Composites ◽  
Work Piece ◽  
Matrix Composites ◽  
Peak Current ◽  
Hollow Electrode

Aimed at the problems of the conventional electrical discharge machining of particle-reinforced aluminum matrix composites (PR-AMCs), a novel hollow hexagonal electrode has been employed and the influence of the electrode structure on the MRR has been investigated. In this study, 3-D model of the working medium fluid flow field has been established to study the structure effect of the hexagonal electrode. And a lot of single factor comparison experiments are carried out between the hexagonal hollow electrode and round hollow electrode. The effects of peak current, duty cycle, machining rotation speed and pulse width on the MRR of work-piece has been studied respectively. The Response Surface Method (RSM) is adopted to imitate the law of machining surface of the hexagonal hollow electrode. The theoretical and experimental results both show that the MRR of the work-piece can be improved remarkably by using a hexagonal hollow electrode. Moreover, according to the RSM, the maximum MRR of machining AMCs of the hexagonal hollow electrode is 225mm3/min, while the optimum combination of parameters that the peak current (12A), the duty cycle (0.75), machining rotation speed (900 r/min) and flushing pressure (1.5MPa) is exerted.

Analysis of Micro-Pin Manufacturing Using Inverse Slab Electrical Discharge Milling (ISEDM) Process

2011 ◽  
Vol 496 ◽  
pp. 247-252 ◽  
Author(s):  
Ruben Gil ◽  
J.A. Sánchez ◽  
N. Ortega ◽  
S. Plaza ◽  
B. Izquierdo ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Work Piece ◽  
Electrode Wear ◽  
Pulse Off Time

Abstract. This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), using a conventional EDM machine and graphite electrode. The effect of pulse off-time, work piece final diameter and machining length on material removal rate, electrode wear ratio, radial accuracy and surface roughness has been quantified. From the study, optimum strategies that involve the use of different EDM regimes for achieving the optimum requirements can be defined. Micro-pins of 0.3 mm diameter with aspect ratio as high as 100:1 have been successfully manufactured.

Machining performance of 3D-printed ABS electrode coated with copper in EDM

2019 ◽  
Vol 25 (7) ◽  
pp. 1224-1231 ◽  
Author(s):  
Ujwal A. Danade ◽  
Shrikant D. Londhe ◽  
Rajesh M. Metkar
Keyword(s):  
Fused Deposition Modeling ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Work Piece ◽  
Electrode Wear ◽  
Machining Performance ◽  
Solid Electrode ◽  
Content Type ◽  
Fused Deposition ◽  
Pulse On Time

Purpose Rapid tooling (RT) technique using rapid prototyping (RP) process has been looked upon as an approach which reduces time and cost of production. This study aims to produce electrode for electrical discharge machining (EDM) from acrylonitrile butadiene styrene (ABS) material using the fused deposition modeling (FDM) process of RP. The electrode is coated with copper to a depth of 1 mm by using electroplating to make it conductive. This electrode is termed as RP electrode. The performance of RP electrode having square shape is compared with that of solid electrode of copper having identical size. Design/methodology/approach In this study, the work piece material is chosen to be titanium Grade-V alloy (Ti-Al6-V4). The input parameters on the EDM machine such as discharge current, pulse on time and voltage are studied, and experiments are designed using the Taguchi method. Findings The results pertaining to the material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra) are reported. It is found that the performance of a coated RP electrode is equally satisfactory when compared with that of a solid electrode. Originality/value This paper reports the machining performance of a square-shaped ABS electrode coated with copper. This technique, particularly when the electrode is of intricate shape, saves on cost and time of production of electrode to be used for EDM.

scholarly journals A STUDY ON CAPABILITIES OF DIFFERENT ELECTRODE MATERIALS DURING ELECTRICAL DISCHARGE MACHINING (EDM)

2017 ◽  
Vol 18 (2) ◽  
pp. 189-195
Author(s):  
Muataz Hazza Faizi Al Hazza
Keyword(s):  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Desirability Function ◽  
304 Stainless Steel ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Electrode Wear ◽  
Copper Aluminum ◽  
Full Factorial

Electrode material inelectro discharge machining EDM process plays an important role in terms of material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). The purpose of this research is to investigate the capability of different electrode materials: copper, aluminum and graphite in EDM of AISI 304 stainless steel as a work piece. The research focuses on three current settings: 2.5A, 4.5A and 6.5A using kerosene as dielectric fluid. The experiment is planned and analyzed using full factorial of the experimental design using response surface methodology (RSM). two outputs have been investigated: MRR and EWR. The results indicated that the responses increased with the increase in current. Finally the desirability function method have been used to determine the optimum values. The resulat show that the maximum MRR and  the minimum EWR were achieved by using graphite electrode at current 6.5A.

Machinability of Inconel 625 Aerospace Material Using Cryogenically Treated WEDM

2017 ◽  
Vol 266 ◽  
pp. 38-42 ◽  
Author(s):  
Ashish Goyal ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Electrical Discharge Machining ◽  
Inconel 625 ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Peak Current ◽  
Aerospace Material ◽  
Stock Removal ◽  
Pulse On Time ◽  
Pulse Off Time

Machinability of aerospace material, Inconel 625 through Wire cut electrical discharge machining has been performed and compared using Taguchi’s Orthogonal L18 (21*35). Normal diffused and cryogenic treated diffused wires are being used as a tool electrode to investigate the effects of machining parameters viz. tool electrode, peak current, pulse on time, pulse off time, wire feed and wire tension on the response MRR. The present study resulted that cryogenic treated tool electrode give better performance in comparison to normal wire electrode assisting in improving stock removal and less electrode wear. Pulse on time and peak current are observed as the most influenced parameter. Scanning Electron Microscopy (SEM) studies has been conducted and presented.

Comparison of Conventional and Dry Electrical Discharge Machining

2015 ◽  
Vol 794 ◽  
pp. 278-284 ◽  
Author(s):  
Tassilo Maria Schimmelpfennig ◽  
Ivan Perfilov ◽  
Jan Streckenbach ◽  
Eckart Uhlmann
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Design ◽  
Ceramic Materials ◽  
Electrode Wear ◽  
Statistical Design Of Experiments ◽  
Aspect Ratios ◽  
Dry Edm ◽  
Micro Holes ◽  
Micro Drilling

For manufacturing of micro holes ElectricalDischarge Machining (EDM) can be used, which is well-established due toits thermal working principle that allows almost force free machining independent of the material’s mechanical properties. The importance of this production technology is increasing, especially for the machining of ceramic materials, which are required in many applications within the field of microtechnology. However, the production of precise micro holes with complex geometries and high aspect ratios is associated with a many challenges. Hightool electrode wear, low material removal rate and small gap widths are observed in the process. This paper presents an optimized dry EDM technology for the manufacturing of micro holes in Si3N4-TiNceramic. The experiments were carried out with different energy influencing process parameters for the spark discharge and flushing pressure, which were systematically evaluated by methods of statistical Design of Experiments. Subsequently dry EDM and conventional EDM micro drilling processes were compared and the differences between both processes were evaluated. The influences of liquid and gaseous dielectric are analyzed in terms of process stability and axis movements.

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