Electrochemical Grinding for Unclosed Internal Cylinder Surface

2007 ◽  
Vol 359-360 ◽  
pp. 360-364 ◽  
Author(s):  
Ping Mei Ming ◽  
Di Zhu ◽  
Zheng Yang Xu
Keyword(s):  
Functional Performance ◽  
Aircraft Engine ◽  
Cylinder Surface ◽  
Machining Accuracy ◽  
Electrically Conductive ◽  
Electro Discharge Machining ◽  
Manual Methods ◽  
Passive Alloys ◽  
Electrochemical Grinding ◽  
Edm Process

The electro discharge machining (EDM) process is widely applied to produces surfaces of difficult-to-machine materials that require some form of grinding or finishing operation. This is conducted so as to improve the surface texture and appearance of the component’s surface. However, it is also desirable to remove the white uppermost recast layer or damaged surface layer (produced by the EDM process) in order to improve the functional performance of the surface. The finishing of the surface by traditional manual methods, especially in the operation of small and long internal cylinder surface, is both tedious and time-consuming. A novel electrically conductive diamond mounted point electrochemical grinding (DMP-ECG) process is being developed for hard passive alloys unclosed internal cylinder surface grinding. The process mechanism of DMP-ECG is introduced; the influence parameters of the surface roughness, machining accuracy, and diamond tool wear are investigated experimentally for nickel-based super alloys materials. An application of the DMP-ECG to aircraft engine component is verified in term of the optimized process parameters.

Cathode and its Feeding Path Design in the NC-ECM Process of the Rimed Integral Impeller

2010 ◽  
Vol 426-427 ◽  
pp. 156-160
Author(s):  
Jian She Zhao ◽  
Jia Wen Xu ◽  
N.Z. Yun
Keyword(s):  
Design Process ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Accuracy ◽  
Rough Machining ◽  
Whole Process ◽  
Electro Discharge Machining ◽  
Path Design ◽  
Shaping Process ◽  
Edm Process

At present, the rimed integral impeller is machined mainly by NC-electro-discharge machining (NC-EDM). To raise the efficiency of EDM process, the pre-channel is machined by NC-ECM to replace NC-EDM in rough machining process. The experimental results indicate that the whole process efficiency can be improved by not less than 20%, but the design of cathode and its feeding path in NC-ECM is a skilled and costly work. To improve machining accuracy and simplify design process, a new design approach based on simulating the shaping process of NC-ECM was put forward to design the cathode and its feeding path.

scholarly journals Electrical Discharge Machining (EDM): A Review

2016 ◽  
Vol 1 (1) ◽  
pp. 3-10 ◽  
Author(s):  
Asfana Banu ◽  
Mohammad Yeakub Ali
Keyword(s):  
Thermal Conductivity ◽  
Electrical Resistivity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dielectric Medium ◽  
Melting Points ◽  
Electrically Conductive ◽  
Conductive Material ◽  
Electro Discharge Machining ◽  
Edm Process

Electro discharge machining (EDM) process is a non-conventional and non-contact machining operation which is used in industry for high precision products. EDM is known for machining hard and brittle conductivematerials since it can melt any electrically conductive material regardless of its hardness. The workpiece machined by EDM depends on thermal conductivity, electrical resistivity, and melting points of the materials. The tool and the workpiece are adequately both immersed in a dielectric medium, such as, kerosene, deionised water or any other suitable fluid. This paper is reviewed comprehensively on types of EDM operation. A brief discussion is also done on the machining responses and mathematical modelling.

Novel die-sinking micro-electro discharge machining process using microelectromechanical systems technology

2006 ◽  
Vol 220 (9) ◽  
pp. 1481-1487 ◽  
Author(s):  
J-B Li ◽  
K Jiang ◽  
G J Davies
Keyword(s):  
Microelectromechanical Systems ◽  
Machining Process ◽  
Metallic Surface ◽  
Manufacturing Cost ◽  
Sem Images ◽  
Deep Reactive Ion Etching ◽  
Electro Discharge Machining ◽  
Mems Technology ◽  
Fabrication Condition ◽  
Edm Process

A novel die-sinking micro-electro discharge machining (EDM) process is presented for volume fabrication of metallic microcomponents. In the process, a high-precision silicon electrode is fabricated using deep reactive ion etching (DRIE) process of microelectromechanical systems (MEMS) technology and then coated with a thin layer of copper to increase the conductivity. The metalized Si electrode is used in the EDM process to manufacture metallic microcomponents by imprinting the electrode onto a flat metallic surface. The two main advantages of this process are that it enables the fabrication of metallic microdevices and reduces manufacturing cost and time. The development of the new EDM process is described. A silicon component was produced using the Surface Technology Systems plasma etcher and the DRIE process. Such components can be manufactured with a precision in nanometres. The minimum feature of the component is 50 μm. In the experiments, the Si component was coated with copper and then used as the electrode on an EDM machine of 1 μm resolution. In the manufacturing process, 130 V and 0.2 A currents were used for a period of 5 min. The SEM images of the resulting device show clear etched areas, and the electric discharge wave chart indicates a good fabrication condition. The experimental results have been analysed and the new micro-EDM process is found to be able to fabricate 25 μm features.

Experimental Study of the Effect of Cryogenic Treatment on the Performance of Electro Discharge Machining

2009 ◽  
Author(s):  
Murali Meenakshi Sundaram ◽  
Yakup Yildiz ◽  
K. P. Rajurkar
Keyword(s):  
Material Properties ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Cold Treatment ◽  
Electrical Energy ◽  
Machining Process ◽  
Deep Cryogenic Treatment ◽  
Electrically Conductive ◽  
Conductive Materials ◽  
Electro Discharge Machining

Cryogenic treatment is a heat treatment process in which the specimen is subjected to an extremely low temperature of the order of −300° F and below, to cause beneficial changes in the material properties. The advantages of cryogenic treatment include relieved residual stresses, and better electrical properties. Electro discharge machining (EDM) is a well known nontraditional machining process in which electrical energy is converted to thermal energy to remove material by melting and evaporation from electrically conductive materials. The process performance of EDM is affected by several factors including the material properties. In this study, the effect of cryogenic treatment on the performance of EDM is investigated experimentally. Copper tool electrodes were subjected to two different treatment methods, namely cold treatment (around −150° F) and deep cryogenic treatment (around −300° F). Using these electrodes, experiments were conducted to study the effect of various process parameters. Significant improvement in material removal rate was observed for EDM with cryogenically treated tools. However, their effect on tool wear is only marginal.

Surface Quality of Cavities Obtained by EDM Process

2011 ◽  
Vol 223 ◽  
pp. 931-939
Author(s):  
Rodrigo Panosso Zeilmann ◽  
Gerson Luiz Nicola ◽  
Fernando Moreira Bordin ◽  
Tiago Vacaro ◽  
Mariana Czarnobay Zanotto
Keyword(s):  
Surface Quality ◽  
Electrical Discharge Machining ◽  
Subsurface Layer ◽  
Side Wall ◽  
Machining Processes ◽  
Electrically Conductive ◽  
Machined Parts ◽  
Edm Process

The electrical discharge machining (EDM) is a process widely used in machining of complex geometries and hardened materials, conditions that often are not met by conventional machining processes. In EDM the electrode reproduces its image or geometry on the part and this image is obtained by chip removing process, which is given by high frequency electrical discharges, causing the melting and vaporization of electrically conductive materials. Due to this mechanism of material removal, the surface is subjected to high thermal loads, which heavily influences the surface quality of obtained parts. For the characterization of these surfaces must be considered the surface topography and the metallurgical changes of the subsurface layer, since both characteristics influence the functionality of the machined parts. In addition, several variables related to the EDM process have influence on the characteristics of the generated surface. This work presents a study of the influence of EDM process on the surface quality of square cavities. It was evaluated different regions of the cavities, such as side wall, bottom and corners. The results showed significant differences between the analyzed regions.

scholarly journals A study of micro-electro discharge machining electrode wear

2007 ◽  
Vol 221 (5) ◽  
pp. 605-612 ◽  
Author(s):  
D T Pham ◽  
A Ivanov ◽  
S Bigot ◽  
K Popov ◽  
S Dimov
Keyword(s):  
Electrode Wear ◽  
Micro Edm ◽  
Volumetric Wear ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Electrode Shape ◽  
Compensation Methods ◽  
Geometrical Information ◽  
Edm Drilling ◽  
Edm Process

This paper studies the influence of factors contributing to electrode wear during the micro-electro discharge machining (EDM) process. The paper proposes a method for calculating the volumetric wear ratio based only on geometrical information obtained from the process. The objective of the work is to investigate the suitability of micro-EDM electrode wear compensation methods. Electrode shape deformation and random variations in the volumetric wear are studied as two main factors affecting the applicability of wear compensation methods as well as indicating the accuracy achievable with micro-EDM. EDM drilling and EDM milling are regarded as separate processes as they require different approaches in investigating and implementing the results of the study.

scholarly journals The accuracy of machining during electro-discharge cutting process using different-diameter electrodes

Mechanik ◽  
2017 ◽  
Vol 90 (11) ◽  
pp. 1000-1002 ◽  
Author(s):  
Jan Burek ◽  
Robert Babiarz ◽  
Jarosław Buk ◽  
Marcin Płodzień ◽  
Paweł Sułkowicz
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Aircraft Engine ◽  
Cutting Process ◽  
Machining Accuracy ◽  
Wire Electrical Discharge Machining ◽  
Heat Resistant Alloy ◽  
Resistant Alloy ◽  
Different Diameters

The WEDM (wire electrical discharge machining) accuracy tests were performed. Electrodes of different diameters were used to cut the blade lock profile of an aircraft engine made from the heat-resistant alloy Inconel 718.

Electro-Discharge Machining of Aluminum Alloy with Nickel Powder-Mixed Dielectric

2018 ◽  
Vol 3 (2) ◽  
pp. 49
Author(s):  
Srinivasa Rao P ◽  
Eshwara Prasad K
Keyword(s):  
Material Removal ◽  
Nickel Powder ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Nickel Concentration ◽  
Powder Concentration ◽  
Electro Discharge Machining ◽  
Nickel Powders ◽  
Electrode Discharge ◽  
Edm Process

Powder-mixed dielectric fluid is one of the innovations of electrode-discharge machining (EDM) which seeks to improve the process outputs by addition of Nickel powders to the dielectric during machining. In the present study, the influence of Nickel powder in kerosene dielectric fluid on EDM process outputs was investigated.  Experiments were conducted with the outputs as material removal rate (MRR) and surface roughness(Ra). During the EDM, the discharge current was varied between 3 and 15 A, while powder concentration ranges between 2 and 10 g/l.  Results indicate that the highest MRR of  39.888 mm3 /min was obtained with Nickel powder concentration of 6 g/l at the current of  9A, where as the lowest SR of  3.397 μm was obtained with Nickel concentration of 3 g/l at the current of 3A.

A Neural Network/Expert System Approach for Design Improvement of Products Manufactured by EDM

1999 ◽  
Vol 121 (4) ◽  
pp. 733-738 ◽  
Author(s):  
Z. Katz ◽  
J. Naude
Keyword(s):  
Neural Network ◽  
Expert System ◽  
Process Parameters ◽  
System Approach ◽  
Comprehensive Analysis ◽  
Design Improvement ◽  
Stochastic Nature ◽  
Electro Discharge Machining ◽  
Precise Prediction ◽  
Edm Process

The stochastic nature of the electro discharge machining (EDM) process does not allow for a precise prediction of its effect on the machined features. However, there is a direct interrelation between feature design and the process results. The objective of this work is to suggest a neural network based system to facilitate and optimize the design process of products to be machined by EDM. A comprehensive analysis by a neural network and expert system is presented. Aspects of features coding and relations with the process parameters are discussed. Experimental results confirm design improvements and a practical system is described.

Sign in / Sign up

Export Citation Format

Share Document