Comparative Study on Parametric Analysis of μEDM of Non-Conductive Ceramics

2014 ◽  
Vol 611-612 ◽  
pp. 693-700 ◽  
Author(s):  
Nirdesh Ojha ◽  
Florian Zeller ◽  
Claas Müller ◽  
Holger Reinecke
Keyword(s):  
Comparative Study ◽  
Material Properties ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Open Circuit ◽  
Machining Process ◽  
Machining Parameters ◽  
Sem Images ◽  
Conductive Ceramics

Characterized by excellent material properties such has high mechanical, thermal and chemical stability technical ceramics such as ZrO2, SiC, Si3N4and AlN are increasingly being used for various applications. Traditional means of machining sintered ceramics are expensive and limited by geometry. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer (denoted as assisting electrode) on top of the non-conductive material, the EDM process can also be used to structure insulating ceramics. This paper presents a comparative study on the major machining parameters affecting the µEDM process of non-conductive SiC, ZrO2, Si3N4and AlN ceramics. The influence of five major machining parameters (current, open-circuit voltage, gap voltage, duty-cycle and servo) over two responses (material removal rate (MRR) and tool wear rate) is investigated for each ceramics material. The underlying reason for the variation in the MRR among the different ceramics is examined by comparing the material properties. Melting point of the ceramics material has an effect on the MRR for the µEDM of different ceramics. The bulk resistance value of the ceramic material does not have an influence on the MRR for the µEDM of different ceramics. Scanning electron microscope (SEM) images of the cross section of the unprocessed and µEDM processed surface of these ceramics have been analyzed. The SEM micrographs show that the µEDM process does not affect the ceramics bulk. It also confirmed spalling as one of the dominant material removal mechanism for ZrO2ceramics.

Study on the Effect of Tool Polarity and Tool Rotation during EDM of Non-Conductive Ceramics

2014 ◽  
Vol 941-944 ◽  
pp. 2127-2133 ◽  
Author(s):  
Nirdesh Ojha ◽  
Florian Zeller ◽  
Claas Mueller ◽  
Holger Reinecke
Keyword(s):  
Material Properties ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ceramic Materials ◽  
Machining Process ◽  
Electrode Wear ◽  
Conductive Material ◽  
Tool Rotation ◽  
Edm Process

The ability to machine advanced ceramic materials such as ZrO2, SiC, and AlN is of high interest for various industries because of the extraordinary material properties that these ceramics possess. Once sintered, these ceramics are characterized with high mechanical strength, high thermal stability and high chemical inertness. Therefore it is extremely difficult to machine these ceramics with dimensions in few microns using traditional techniques. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer on top of the non-conductive material, the EDM process can also be used to machine the non-conductive material. This paper presents a study on the effect of tool polarity and tool rotation on the material removal rate and electrode wear ratio during the EDM process of non-conductive SiC, ZrO2 and AlN ceramics. The reasons for the variation in the material removal rates among the different ceramics are examined by comparing the material properties. Relatively lower value of flexural strength, fracture toughness and melting temperature is the reason for AlN ceramic to have the higher MRR than SiC and ZrO2 ceramics.

scholarly journals A Comprehensive Study on Processing Ti–6Al–4V ELI with High Power EDM

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 303
Author(s):  
Panagiotis Karmiris-Obratański ◽  
Emmanouil L. Papazoglou ◽  
Beata Leszczyńska-Madej ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
High Power ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Performance

Electrical Discharge Machining (EDM) consists of a non-conventional machining process, which is widely used in modern industry, and especially in machining hard-to-cut materials. By employing EDM, complex shapes and geometries can be produced, with high dimensional accuracy. Titanium alloys, due to their unique inherent properties, are extensively utilized in high end applications. Nevertheless, they suffer from poor machinability, and thus, EDM is commonly employed for their machining. The current study presents an experimental investigation regarding the process of Ti–6Al–4V ELI with high power EDM, using a graphite electrode. Control parameters were the pulse-on current (Ip) and time (Ton), while Machining performances were estimated in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The machined Surface Roughness was calculated according to the Ra and the Rt values, by following the ISO 25178-2 standards. Furthermore, the EDMed surfaces were observed under optical and SEM microscopy, while their cross sections were also studied in order the Average White Layer Thickness (AWLT) and the Heat Affected Zone (HAZ) to be measured. Finally, for the aforementioned indexes, Analysis Of Variance was performed, whilst for the MRR and TMRR, based on the Response Surface Method (RSM), semi-empirical correlations were presented. The scope of the current paper is, through a series of experiments and by employing statistical tools, to present how two main machining parameters, i.e., pulse-on current and time, affect major machining performance indexes and the surface roughness.

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.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

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.

Enhancing the Surface Quality by Iso Pulse Generator in EDM Process

2012 ◽  
Vol 622-623 ◽  
pp. 380-384 ◽  
Author(s):  
T. Muthuramalingam ◽  
B. Mohan
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Discharge Energy ◽  
Crater Volume ◽  
Machining Characteristics ◽  
Edm Process

In automobile and aeronautical industries, complex moulds and dies is produced by Electrical Discharge Machining process. The surface finish is determined by the crater volume in EDM process. The amount of crater volume is influenced by the amount and distribution of discharge energy. The discharge energy is directly proportional to the average discharge current. This amount of current is determined by the duration of discharging effect. This study deals about evaluating the performance of iso current pulse generator on machining characteristics in EDM. Due to its ability of reducing stochastic nature in EDM process, iso pulse generator could produce better surface finish than conventional transistor pulse train generator with higher material removal rate.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

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