Simulation on Material Removal during Reciprocating Traveling WEDM of Insulating Ceramics

2013 ◽  
Vol 690-693 ◽  
pp. 2490-2495
Author(s):  
Yong Feng Guo ◽  
Peng Ju Hou ◽  
Liu Xian Sun ◽  
Li Wang ◽  
Zong Feng Li
Keyword(s):  
Pulse Duration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Layer Structure ◽  
Machining Process ◽  
Movement Speed ◽  
Wire Electrode ◽  
Conductive Layer ◽  
Peak Current ◽  
Insulating Ceramics

With the double layer structure model, the material removal of insulating ceramics ZrO2 during the machining process by reciprocating traveling wire electrical discharge machining (WEDM) was simulated and analyzed. The influence of conductive layer (C and ZrC) to material removal volume and crater dimension was compared. And the effect of peak current, pulse duration and the movement speed of wire electrode on discharge craters were researched. The simulation shows that the conductive layer exist has much influence to the material removal volume and crater length and width, but has less influence to crater depth during electrical discharge. The simulation for the effect of discharge parameter tells that, with the boiling removal form hypothesis, the material removal volume during single discharge is increasing with the increment of peak current and pulse duration but decreasing with the raising of wire electrode movement speed. For the variation of peak current, the removal volume of ZrO2 is exceeding the removal volume of conductive layer when Ip is bigger than 24A. Meanwhile, for the variation of movement speed of wire electrode, the removal volume of conductive layer is more than that of ZrO2 when v is over 5m/s.

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

scholarly journals Effect of Peak Current on Material Removal Rate for Electrical Discharge Machining of Non-Conductive Al2O3 Ceramic

2013 ◽  
Vol 845 ◽  
pp. 730-734 ◽  
Author(s):  
M.A. Moudood ◽  
A. Sabur ◽  
Mohammad Yeakub Ali ◽  
I.H. Jaafar
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Machining Process ◽  
Tool Electrode ◽  
Peak Current ◽  
Assisting Electrode

Electrical discharge machining (EDM) is a non-conventional machining process where materials are removed by the thermal energy exerted from series of electrical sparks. This process is applied for machining of non-conductive alumina (Al2O3). The workpiece is covered with the adhesive copper foil to initiate the initial spark between the workpiece and the tool electrode. A pyrolytic carbon (PyC) layer is generated on workpiece surface by dissociating kerosene dielectric after the machining of initial copper assisting electrode (AE) layer. In this study, experiments were performed by varying the peak current and keeping other parameters constant in order to investigate the effect of peak current on material removal rate (MRR) in EDM of Al2O3. The results showed that the lowest and the highest values of peak current were 1.1 A and 1.3 A, respectively. Material cannot be removed due to insufficient PyC layer generation for any values of peak current less than 1.1 A or more than 1.3 A. From the results, it is also observed that the MRR is increased when higher peak current values are used. MRR was found to be 0.052 mm3/min at peak current 1.1 A and it was found to be 0.132 mm3/min at peak current 1.3 A.

High Performance in EDM Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 500 ◽  
pp. 259-265 ◽  
Author(s):  
Faizul Ezmat Abdul Hamid ◽  
Mohd Amri Lajis
Keyword(s):  
Pulse Duration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
High Performance ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Hardened Steel ◽  
Peak Current ◽  
Aisi D2

In this paper an attempt has been made to investigate the performance of an electrode made through powder metallurgy (PM) of copper tungsten during electrical discharge machining (EDM). Experimental results are presented on electrical discharge machining of AISI D2 hardened steel in kerosene with a copper tungsten (Cu35% - W65%) tool electrode made through PM method with a constant duty factor of 80%. In term of high performance EDM process, higher peak current (>20A) and pulse duration (>400µs) with a high machining efficiency were used. Experimental results have shown that machining at a peak current of 40A and pulse duration of 400µs yields the highest material removal rate (MRR) whereas machining at a peak current of 20A and pulse duration of 400µs yields the lowest tool wear rate (TWR). The lowest surface roughness appears at the lowest material removal rate which is at a peak current of 20A and pulse duration of 600µs. The optimum machining performance can be performed by the combination of pulse duration and peak current at 600µs and 40A respectively.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

scholarly journals Wire Electrical Discharge Machining—A Review

Machines ◽  
2020 ◽  
Vol 8 (4) ◽  
pp. 69
Author(s):  
Laurenţiu Slătineanu ◽  
Oana Dodun ◽  
Margareta Coteaţă ◽  
Gheorghe Nagîţ ◽  
Irina Beşliu Băncescu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrode ◽  
Machining Processes ◽  
Scientific Papers ◽  
The Wire ◽  
Machining Productivity ◽  
Machined Surfaces

Wire electrical discharge machining has appeared mainly in response to the need for detachment with sufficiently high accuracy of parts of plate-type workpieces. The improvements introduced later allowed the extension of this machining technology to obtain more complex ruled surfaces with increasingly high requirements regarding the quality of the machined surfaces and the productivity of the wire electrical discharge machining process. Therefore, it was normal for researchers to be interested in developing more and more in-depth investigations into the various aspects of wire electrical discharge machining. These studies focused first on improving the machining equipment, wire electrodes, and the devices used to position the clamping of a wire electrode and workpiece. A second objective pursued was determining the most suitable conditions for developing the machining process for certain proper situations. As output parameters, the machining productivity, the accuracy, and roughness of the machined surfaces, the wear of the wire electrode, and the changes generated in the surface layer obtained by machining were taken into account. There is a large number of scientific papers that have addressed issues related to wire electrical discharge machining. The authors aimed to reveal the aspects that characterize the process, phenomena, performances, and evolution trends specific to the wire electrical discharge machining processes, as they result from scientific works published mainly in the last two decades.

Effect of Frequency to Ultrasonic Vibration-Assisted Wire-EDM

2019 ◽  
Vol 814 ◽  
pp. 127-131
Author(s):  
Patittar Nakwong ◽  
Apiwat Muttamara
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Machining Process ◽  
Wire Electrode ◽  
Ultrasonic Machine ◽  
Lower Amplitude ◽  
Wedm Process

Wire electrical discharge machine (WEDM) is non-conventional machining process. It can be used for hard cutting material. The study has been presented the combining WEDM with an ultrasonic machine (USM) with brass and tungsten were used as a wire electrode and workpiece respectively. The experiment was carried out with an ultrasonic transducer at 40, 80 kHz. The results were observed with the material removal rate (MRR) and surface roughness (Ra). This research introduced the method of USM setup and described the effected of vibration with the wire electrode on the displacement of amplitude. The result shows that the WEDM process with USM at 40 kHz can be more improved with the material removal rate and surface roughness than that of USM at 80 kHz. This can be explained that higher frequency affected to vibration displacement which makes lower amplitude.

Modeling of Material Removal in Atomized Dielectric-Based Electrical Discharge Machining (EDM)

2019 ◽  
Author(s):  
Asif Tanveer ◽  
Shiv G. Kapoor ◽  
Soham S. Mujumdar
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Film Flow ◽  
Electrical Discharge Machining ◽  
Dielectric Film ◽  
Machining Process ◽  
Spray Parameters ◽  
Melt Pool ◽  
Material Removal Model ◽  
Pool Formation

Abstract Atomized dielectric-based electrical discharge machining (EDM) is an emerging technology in which the dielectric between the electrodes is supplied in the form of a thin film using a spray atomizer. This novel machining process uses significantly less quantities of dielectric compared to the conventional EDM while resulting in higher material removal rates and better debris flushing. This paper presents a model-based investigation of the atomized dielectric-based EDM to study the effect of the dielectric film flow on material removal. A melt-pool formation and material removal model is developed to predict the material removal in terms of crater shapes during a single EDM discharge. The atomization spray parameters are varied in order to produce different dielectric film velocities. The model accurately captures the asymmetry in crater shapes caused by the dielectric film flow and predicts the crater diameter and depth, however, the model overestimates the crater sizes observed in experiments.

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

2020 ◽  
Vol 235 (1-2) ◽  
pp. 125-133
Author(s):  
Omer Eyercioglu ◽  
Kursad Gov
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Magnesium Content ◽  
Machining Process ◽  
Electrode Wear ◽  
Ti Alloy ◽  
Ti Alloys ◽  
Mg Content

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

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