Study of Micro-EDM of Tungsten Carbide with Workpiece Vibration

2011 ◽  
Vol 264-265 ◽  
pp. 1056-1061 ◽  
Author(s):  
Muhammad Pervej Jahan ◽  
T. Saleh ◽  
Mustafizur Rahman ◽  
Yoke San Wong
Keyword(s):  
Tungsten Carbide ◽  
Surface Quality ◽  
Removal Rate ◽  
Low Frequency ◽  
Electrode Wear ◽  
Micro Edm ◽  
Machining Performance ◽  
Machining Time ◽  
Workpiece Vibration ◽  
Micro Holes

Present study introduces low-frequency workpiece vibration during micro-EDM drilling of difficult-to-cut tungsten carbide with an objective to overcome the difficulty in flushing of debris and machining instability in deep-hole machining. The effects of vibration frequency, amplitude and electrical parameters on the machining performance, as well as surface quality and accuracy of the micro-holes have been investigated. It is found that the overall machining performance improves significantly with significant reduction of machining time, increase in material removal rate (MRR), and decrease in electrode wear ratio (EWR). The surface quality improves and the overcut and taper angle of the micro-holes reduces after applying the workpiece vibration in micro-EDM. The frequency and amplitude of 750 Hz and 1.5 μm were found to provide optimum performance.

Development, Modeling, and Experimental Investigation of Low Frequency Workpiece Vibration-Assisted Micro-EDM of Tungsten Carbide

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
M. P. Jahan ◽  
T. Saleh ◽  
M. Rahman ◽  
Y. S. Wong
Keyword(s):  
Tungsten Carbide ◽  
Fluid Pressure ◽  
Low Frequency ◽  
Dielectric Fluid ◽  
Micro Edm ◽  
Contributing Factors ◽  
Machining Performance ◽  
Machining Time ◽  
Workpiece Vibration ◽  
Improved Performance

This present study intends to investigate the feasibility of drilling deep microholes in difficult-to-cut tungsten carbide by means of low frequency workpiece vibration-assisted micro–electro-discharge machining (micro-EDM). A vibration device has been designed and developed in which the workpiece is subjected to vibration of up to a frequency of 1 kHz and an amplitude of 2.5 μm. An analytical approach is presented to explain the mechanism of workpiece vibration-assisted micro-EDM and how workpiece vibration improves the performance of micro-EDM drilling. The reasons for improving the overall flushing conditions are explained in terms of the behavior of debris in a vibrating workpiece, change in gap distance, and dielectric fluid pressure in the gap during vibration-assisted micro-EDM. In addition, the effects of vibration frequency, amplitude, and electrical parameters on the machining performance, as well as surface quality and accuracy of the microholes have been investigated. It has been found that the overall machining performance improves considerably with significant reduction of machining time, increase in MRR, and decrease in EWR. The improved flushing conditions, increased discharge ratio, and reduced percentage of ineffective pulses are found to be the contributing factors for improved performance of the vibration-assisted micro-EDM of tungsten carbide.

EXPERIMENTAL INVESTIGATION OF MICRO-EDM OPERATION IN INCONEL 718

2021 ◽  
pp. 2150102
Author(s):  
MAYANK CHOUBEY ◽  
K. P. MAITY
Keyword(s):  
Experimental Investigation ◽  
Inconel 718 ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Machining Processes ◽  
Machining Time ◽  
Machine Material ◽  
Micro Holes ◽  
Unconventional Machining

The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

scholarly journals Technical Model of Micro Electrical Discharge Machining (EDM) Milling Suitable for Bottom Grooved Micromixer Design Optimization

Micromachines ◽  
2020 ◽  
Vol 11 (6) ◽  
pp. 594 ◽  
Author(s):  
Izidor Sabotin ◽  
Gianluca Tristo ◽  
Joško Valentinčič
Keyword(s):  
Design Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Micro Edm ◽  
Efficient Design ◽  
Machining Time ◽  
Micro Electrical Discharge Machining ◽  
Technical Model

In this paper, development of a technical model of micro Electrical Discharge Machining in milling configuration (EDM milling) is presented. The input to the model is a parametrically presented feature geometry and the output is a feature machining time. To model key factors influencing feature machining time, an experimental campaign by machining various microgrooves into corrosive resistant steel was executed. The following parameters were investigated: electrode dressing time, material removal rate, electrode wear, electrode wear control time and machining strategy. The technology data and knowledge base were constructed using data obtained experimentally. The model is applicable for groove-like features, commonly applied in bottom grooved micromixers (BGMs), with widths from 40 to 120 µm and depths up to 100 µm. The optimization of a BGM geometry is presented as a case study of the model usage. The mixing performances of various micromixer designs, compliant with micro EDM milling technology, were evaluated using computational fluid dynamics modelling. The results show that slanted groove micromixer is a favourable design to be implemented when micro EDM milling technology is applied. The presented technical model provides an efficient design optimization tool and, thus, aims to be used by a microfluidic design engineer.

Influence of Material Microstructure on Micro EDM

2011 ◽  
Vol 130-134 ◽  
pp. 927-930
Author(s):  
Jian Zhong Li ◽  
Fei Hu Shen ◽  
Mei Gang Guo
Keyword(s):  
Material Properties ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Machining Performance ◽  
Material Microstructure ◽  
Workpiece Material ◽  
Micro Holes

In conventional electrical discharge machining (EDM), the workpiece material is considered as homogenous material. When a micro feature is machined in alloy by micro EDM, microstructure of alloy may be of the same order as the micro feature. This may lead to the variation of machining performance of micro EDM. This paper demonstrates the influence of material microstructure on the machining performance by drilling micro holes within the crystal grain and on the boundary of TA0-1. Experimental results indicate that the average values of material removal rate, tool wear ratios and the discharge gaps on different locations are different because their material properties are different.

Investigation of Cryogenic Cooling of Micro EDM Drilling Process on AISI 304 Stainless Steel

2016 ◽  
Author(s):  
Manivannan Raja ◽  
Pradeep Kumar Murugasen ◽  
Hariharan Periannapillai
Keyword(s):  
Removal Rate ◽  
Cryogenic Cooling ◽  
304 Stainless Steel ◽  
Drilling Process ◽  
Electrode Wear ◽  
Micro Edm ◽  
Aisi 304 ◽  
Micro Holes ◽  
Pulse Off Time

In this experimental work, the cryogenic cooling of the Micro-EDM (μEDM) drilling process for improving the performance and quality of micro holes. The controllable parameters such as the current (Ip), pulse on time (Ton), Pulse off time (Toff) and gap voltage (Vg) were chosen for further investigation. The Taguchi L27 orthogonal array is preferred to achieve the best experimental runs. Case hardened AISI 304 stainless steel is selected to perform the experiments. The overall machining performances of geometrical characterization such as taper angle, Overcut, Circularity at the entry and exit and the performance evaluation such as the material removal rate and electrode wear rate are analyzed. It is found that the taper angle improved by 91%, overcut improved by 17 to 66%, Circularity improved up to 70% and 68% respectively, material removal rate increased from 9 to 70% and electrode wear rate reduced up to 76%. It is found that pulse off time plays a vital role in the quality of micro holes drilled in both conventional and cryogenic micro-EDM (CμEDM) processes.

scholarly journals Performance Evaluation and Comparison between Direct and Chemical-Assisted Picosecond Laser Micro-Trepanning of Single Crystalline Silicon

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 41 ◽  
Author(s):  
Hao Zhu ◽  
Zhaoyang Zhang ◽  
Kun Xu ◽  
Jinlei Xu ◽  
Shuaijie Zhu ◽  
...  
Keyword(s):  
Material Removal ◽  
Crystalline Silicon ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Orthogonal Experimental Design ◽  
Single Crystalline Silicon ◽  
Machining Performance ◽  
Single Crystalline ◽  
Direct Laser ◽  
Micro Holes

The fabrication of micro-holes in silicon substrates that have a proper taper, higher depth-to-diameter ratio, and better surface quality has been attracting intense interest for a long time due to its importance in the semiconductor and MEMS (Micro-Electro-Mechanical System) industry. In this paper, an experimental investigation of the machining performance of the direct and chemical-assisted picosecond laser trepanning of single crystalline silicon is conducted, with a view to assess the two machining methods. The relevant parameters affecting the trepanning process are considered, employing the orthogonal experimental design scheme. It is found that the direct laser trepanning results are associated with evident thermal defects, while the chemical-assisted method is capable of machining micro-holes with negligible thermal damage. Range analysis is then carried out, and the effects of the processing parameters on the hole characteristics are amply discussed to obtain the recommended parameters. Finally, the material removal mechanisms that are involved in the two machining methods are adequately analyzed. For the chemical-assisted trepanning case, the enhanced material removal rate may be attributed to the serious mechanical effects caused by the liquid-confined plasma and cavitation bubbles, and the chemical etching effect provided by NaOH solution.

scholarly journals An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6074
Author(s):  
Tingting Ni ◽  
Qingyu Liu ◽  
Zhiheng Chen ◽  
Dongsheng Jiang ◽  
Shufeng Sun
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Deionized Water ◽  
Micro Edm ◽  
Nano Particle ◽  
Machining Performance ◽  
Machined Surface ◽  
Micro Electrical Discharge Machining ◽  
Lower Tool

Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

The Machining Characteristics of Insulating AlN Ceramics by EDM

2012 ◽  
Vol 523-524 ◽  
pp. 328-331
Author(s):  
Kensei Kaneko ◽  
Ken Yamashita ◽  
Yasushi Fukuzawa
Keyword(s):  
Thermal Conductivity ◽  
Removal Rate ◽  
Ceramic Materials ◽  
High Thermal Conductivity ◽  
Electrode Wear ◽  
Machining Time ◽  
Laser Method ◽  
Wear Ratio ◽  
Machining Properties ◽  
Machining Characteristics

AlN ceramic materials have high thermal conductivity and electrical insulation, prompting consideration of their use as a semiconducting material. Although AlN should be machined with a high accuracy of form and dimension to achieve products and components with requisite precision, mechanical and other machining methods such as the micro blasting technology or laser method cannot be used because of the brittleness and high thermal conductivity of AIN. Recently, we have succeeded in machining many insulating ceramics by EDM with the assisting electrode method. We have already machined many insulating ceramic materials such as Si3N4, ZrO2 and Al2O3. However, inferior machining characteristics were obtained with AlN than with other materials. In this study, the effects of several electrical discharge conditions were examined to obtain better machining properties, such as high material removal rate and a low electrode wear ratio. It was found that machining time decreased with an increase in capacitance, while the electrode wear ratio increased. In addition, the machining hole profiles were straight along the depth direction, and the shape of holes was non-tapered

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