Residual Stress Analysis of Polycrystalline Diamond after Electrical Discharge Machining

2013 ◽  
Vol 820 ◽  
pp. 106-109 ◽  
Author(s):  
M. Zulafif Rahim ◽  
Arash Pourmoslemi ◽  
Song Lin Ding ◽  
John Mo
Keyword(s):  
Residual Stress ◽  
Electrical Discharge ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
High Hardness ◽  
Machining Process ◽  
Hard Materials ◽  
Advanced Machining ◽  
Pcd Tools

The extreme hardness of Polycrystalline Diamond (PCD) makes it an ideal choice for the machining of hard materials as a cutting tool. Due to the high hardness, fabrication of PCD tools relies on conventional abrasive grinding which suffers from low machining efficiency. Electrical discharge machining (EDM) is an advanced machining process and can be utilised to fabricate complicated PCD tools. High temperature of sintering and EDM processes creates residual stress inside PCD and can result in unmatured failure of PCD tools. This paper analyses the distribution of residual stress in PCD after electrical discharge machining process.

Electrical Discharge Grinding (EDG) of Polycrystalline Diamond - Effect of Machining Polarity

2014 ◽  
Vol 1025-1026 ◽  
pp. 628-632 ◽  
Author(s):  
Mohammad Zulafif Rahim ◽  
Song Lin Ding ◽  
John Mo
Keyword(s):  
Electrical Discharge ◽  
Complex Geometry ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Morphological Examination ◽  
Carbon Structure ◽  
Finishing Process ◽  
Advanced Machining ◽  
The Difference ◽  
Pcd Tools

Electrical discharge grinding (EDG) is an advanced machining process and can be utilised to fabricate complex geometry of PCD tools. However, the PCD removal mechanism in this process is complicated. This study was carried out to understand the difference in PCD surface structure with difference EDG polarities. The study revealed that the finishing process with negative polarity is the reason for the porous structure on the surface. Further analysis on the chemical element and carbon structure were implemented as the morphological examination of the surface.

Effect of impregnated powder materials on surface integrity aspects of Inconel 625 during electrical discharge machining

2016 ◽  
Vol 232 (7) ◽  
pp. 1259-1272 ◽  
Author(s):  
Gangadharudu Talla ◽  
Soumya Gangopadhyay ◽  
CK Biswas
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Integrity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Inconel 625 ◽  
Powder Materials ◽  
Powder Concentration ◽  
Pulse On Time

In recent times, nickel-based super alloys are widely utilized in aviation, processing, and marine industries owing to their supreme ability to retain the mechanical properties at elevated temperature in combination with remarkable resistance to corrosion. Some of the properties of these alloys such as low thermal conductivity, strain hardening tendency, chemical affinity, and presence of hard and abrasives phases in the microstructure render these materials very difficult-to-cut using conventional machining processes. In this work, an experimental setup was developed and integrated with the existing electrical discharge machining system for carrying out powder-mixed electrical discharge machining process for Inconel 625. The experiments were planned and conducted by varying five different variables, that is, powder concentration, peak current, pulse-on time, duty cycle, and gap voltage based on the central composite design of response surface methodology. Effects of these parameters along with powder concentration were investigated on various surface integrity aspects including surface morphology, surface roughness, surface microhardness, change in the composition of the machined surface, and residual stress. Results clearly indicated that addition of powder to dielectric has significantly improved surface integrity compared to pure dielectric. Among the powders used, silicon has resulted in highest microhardness, that is, almost 14% more than graphite. Lowest surface roughness (approximately 50% less than pure kerosene) and least residual stress were obtained using silicon powder (approximately 8% less than graphite-mixed dielectric). Relative content of nickel was reduced at the expense of Nb and Mo after addition of powders like aluminum and graphite in dielectric during electrical discharge machining.

Study on EDM Machining Technics of Polycrystalline Diamond Cutting Tool and PCD Cutting Tool’s Life

2011 ◽  
Vol 268-270 ◽  
pp. 309-315 ◽  
Author(s):  
Yun Hai Jia ◽  
Jian Gang Li ◽  
Xue Jun Lu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Machining Parameter ◽  
Diamond Cutting Tool ◽  
The Relationship

The Samples of Polycrystalline Diamond (PCD) Cutting Tool Were Machined by Adjusting the Main Parameters of Electrical Discharge Machining (EDM). after the Machining, the Phases Were Analyzed by X-Ray Diffraction Analyzer and the Surface Layer Microstructure Were Observed by Scanning Electronic Microscope. the Fundamental Component of Machined PCD Cutting Tool Affected Layer Was Obtained and the Reason of Bring Affected Layer Was Analyzed. the Relationship Curves between Pulse Width, Working Electric Current and Depth Affected Layer, Surface Roughness Were Summarized. the Relationship between PCD Cutting Tools that Was Machined by EDM and Cutting Tool Flank Width, Workpiece Surface Roughness Were Analyed.The Results Showed that to Adjust Electical Discharge Machining Parameter, such as Pulse Width and Machining Electric Currents, Can Reduce the Depth of Affect Layer and Extend the Service Life of PCD Cutting Tool.These Researches Provide Valuable Test Reference for Drawing up Electrical Discharge Machining Technics of PCD Cutting Tool and Cutting Tool’s Life.

ELECTRICAL DISCHARGE GRINDING VERSUS ABRASIVE GRINDING IN POLYCRYSTALLINE DIAMOND MACHINING

2015 ◽  
Vol 74 (10) ◽  
Author(s):  
M. Zulafif Rahim ◽  
Guangxian Li ◽  
Songlin Ding ◽  
John Mo
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Electrical Discharge ◽  
Polycrystalline Diamond ◽  
Quality Indices ◽  
Diamond Machining ◽  
Quality Issue ◽  
Stress Directions ◽  
Conventional Grinding ◽  
Pcd Tools

Electrical Discharge Grinding (EDG) and conventional grinding are two different processes with different removal mechanisms and are typically used to machine Polycrystalline Diamond (PCD). This paper addresses the quality issue of PCD tools produced by these two processes in machining sharp cutting edges. Closely similar visible quality indices (surface roughness and tool sharpness) have been obtained by both processes. However, it was found that there is a difference in residual stress directions and graphitization levels. Through the Raman method, the quantitative analysis of residual stress and graphitization inherence by both processes were also presented and discussed in detail. 

scholarly journals A Research on Machinability of Bio Implant by Electric Discharge Machining Process

2019 ◽  
Vol 8 (4S2) ◽  
pp. 260-263
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Work Piece ◽  
Implant Materials ◽  
Hard Materials ◽  
Electro Discharge Machining ◽  
Current Scenario ◽  
Conventional Machine ◽  
Increasing Demand

Increasing demand in industries to manufacturing the complex geometric shape and hard materials parts is extremely difficult to cut by the conventional machining process. The non-conventional machine is used for the manufacturing of 3D complex and geometry shapes without compromise the required specification. Electro discharge machining (EDM) is a non-traditional machining process, which is very widely used in recent days. EDM process is electrical and thermal energy generated between work piece and an electrode. The major applications are dies, moulds, aerospace parts, automotive industry, and surgical components. The human implant materials like Stainless Steel, Titanium and Co-Cr based alloys are widely used in biomedical fields. This paper shows that fundamental studies on electrical discharge machining (EDM), Wire electrical discharge machining (WEDM) and human implant materials with newly developed advance technologies in the current scenario.

Development of Trends and Methodologies for Shaping Ceramics by Electrical Discharge Machining: A Review

2019 ◽  
Author(s):  
Asif Rashid ◽  
Muhammad P. Jahan ◽  
Asma Perveen ◽  
Jianfeng Ma
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Machining Process ◽  
Future Research ◽  
Great Resistance ◽  
Hard And Brittle Materials ◽  
Superior Corrosion Resistance

Abstract Ceramic materials possess excellent properties like high hardness, superior corrosion resistance and great resistance to wear. These materials are low in density and demonstrate high strength to wear ratio. There is an increasing need to machine these hard and brittle materials as they have various engineering applications. The distinguishing properties of ceramics do not allow them to be machined by conventional processes. Electrical discharge machining (EDM) is a non-conventional process and a viable option to machine and generate complex shapes in hard materials. EDM can be used on materials irrespective of its hardness and wear resistance as it is a non-contact machining process and no active force is applied between the workpiece and electrode during machining. As EDM requires the workpiece to be electrically conductive, machining ceramics by this process is a challenge. Alterations need to be carried out in order for insulating ceramics to be machined by this process. This paper discusses the basics of EDM process and its control parameters. A classification of ceramic materials based on their electrical conductivity is established and their relevance to the respective material removal mechanisms have been identified. Different approaches to successfully machine ceramics by EDM have been reviewed. The challenges and modifications of each method have been discussed. An outline and expectations for machining a particular ceramic material and its composites have been generated. Finally, the prospects of future research in this area have been identified.

scholarly journals The effect of electrical discharge machining parameters on alloy DIN 1.2080 using the Taguchi method and determinant of optimal design of experiments

2017 ◽  
Vol 14 (1) ◽  
pp. 47-64 ◽  
Author(s):  
Pouyan Sadr ◽  
Amin Kolahdooz ◽  
Seyyed Ali Eftekhari
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Hardness ◽  
Machining Parameters ◽  
Hard Materials ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Electrical Discharge Machining (EDM) process is one of the most widely used methods for machining. This method is used to form parts that conduct electricity. This method of machining has used for hard materials and therefore select the correct values of parameters are so effective on the quality machining of parts. D3 steel has a high abrasion resistance at low temperatures therefore can be a good candidate for this method of machining. Also because of high hardness and low distortion during heat treatment, using this method is economical for this alloy. The purpose of this paper is to investigate the influence of the main parameters such as voltage, current, pulse duration and pulse off time and the interaction of them to determine the optimal condition for the D3 steel alloy (alloy with DIN 1.2080). Chip removal rate (MRR) and surface quality of parts were evaluated as the output characteristic of the study. The optimum conditions were achieved when the MRR is in the highest value and surface roughness is in the lowest one. For investigation of interaction, two kinds of DOE methods (Taguchi and determinant of optimal experimental design) are used. Then the optimal parameters are investigated with the help of the analysis signal to noise (S/N) and mathematical modeling. The optimize results were tested again and compared. Also the results showed that regression modeling has better accuracy than the S/N analysis. This is because of a greater number of experiments that done in this part and taking into account the interaction parameters in the regression model.

scholarly journals Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

2019 ◽  
Vol 8 (2S8) ◽  
pp. 1806-1808
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Surface ◽  
High Hardness ◽  
Ceramic Materials ◽  
Machining Process ◽  
Low Efficiency ◽  
Edm Process

Ceramic materials which have high hardness and brittleness cannot be machined by traditional machining process because of their low efficiency and feasibility. But in non-traditional machining process, it overcomes these limitations proving it to be very useful in manufacturing process. In this review paper we are discussing about electrical discharge machining (EDM) process on Al2O3 and Si3N4 ceramic materials which are machine able. EDM parameters like material removal rate (MRR), tool wear rate (TWR), surface finish are discussed. EDM is very much suitable for ceramic materials because of its high surface finish, accuracy and efficiency.

scholarly journals The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

2021 ◽  
Vol 5 (2) ◽  
pp. 34
Author(s):  
Guangxian Li ◽  
Ge Wu ◽  
Wencheng Pan ◽  
Rizwan Abdul Rahman Rashid ◽  
Suresh Palanisamy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Machining Efficiency ◽  
Crater Wear ◽  
Wear Process ◽  
High Speed Turning ◽  
Tools Wear ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

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