scholarly journals Innovative Double Cathode Configuration for Hybrid ECM + EDM Blue Arc Drilling

2021 ◽  
Author(s):  
Jesus M. Orona-Hinojos
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Poor Performance ◽  
Electrical Current ◽  
Dielectric Medium ◽  
Drilling Process ◽  
Workpiece Material ◽  
Drilling Technology ◽  
Drilling Operations

Electrical discharge machining is a machining method generally used for machining hard metals, those that would be high cost or have poor performance to machine with other techniques using, e.g., lathes, drills, or conventional machining. Therefore, also known as thermal processes like EDM, Plasma or Laser cutting can be used in drilling operations with poor metallurgical quality on cutting edge and will be necessary complement with other processes such as electrochemical machining (ECM). Both ECM and EDM processes use electrical current under direct-current (DC) voltage to electrically power the material removal rate (MRR) from the workpiece. However in ECM, an electrically conductive liquid or electrolyte is circulated between the electrode(s) and the workpiece for permitting electrochemical dissolution of the workpiece material. While the EDM process, a nonconductive liquid or dielectric is circulated between the cathode and workpiece to permit electrical discharges in the gap there between for removing the workpiece material. Both are principle too different, EC using an electrical conductive and ED using a dielectric medium. But exist a way that can to do a combination of Pulsed EC + ED Simultaneous and allowing the coexist both process, in a semidielectric medium, where both condition exist in the same time, therefore in this hybrid is possible create a tooling device dual cathode for drilling process with promissory advantages fast hole for this innovative hybrid ECDM Simultaneous, this hybrid it’s knew as blue arc drilling technology.

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.

Cutting Characteristics of Titanium Graphite Composite by Wire Electrical Discharge Machining

2012 ◽  
Vol 630 ◽  
pp. 114-120 ◽  
Author(s):  
Mamidala Ramulu ◽  
Mathew Spaulding ◽  
P. Laxminarayana
Keyword(s):  
Composite Laminates ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Metal Composite ◽  
Workpiece Material ◽  
Graphite Composite ◽  
Wedm Process

To improve strength to weight ratios, the fiber reinforced polymer composite materials are often used in conjunction with another material, like metals, to form hybrid structure. This paper reports the feasibility of using wire electrical discharge machining (WEDM) for cutting Titanium/Graphite Hybrid Composites (TiGr). Slit and slot cuts with WEDM process has been performed. Cutting times and process parameters were recorded, and cut surface characteristics were evaluated both with an optical and scanning electron microscopy (SEM). The results in terms of cutting time, workpiece material removal rate, and damage were presented and discussed. It was found that use of WEDM is possible for machining advanced hybrid metal composite laminates with appropriate machine settings.

scholarly journals Experimental studies of hole drilling operations in stress-strain workpiecematerial

2018 ◽  
Vol 226 ◽  
pp. 01011
Author(s):  
Vadim V. Kuts ◽  
Mikhail S. Razumov ◽  
Aleksandr S. Byshkin
Keyword(s):  
Axial Force ◽  
Experimental Studies ◽  
Hole Drilling ◽  
Drilling Process ◽  
Stress Strain ◽  
Workpiece Material ◽  
South West ◽  
Urgent Task ◽  
Drilling Operations ◽  
Proportionality Limit

Drilling holes is one of the most common operations in the part production. Consequently, increasing the efficiency of this process is an urgent task. To improve the efficiency of the drilling process, the South- West University developed a method of drilling for pre-stressed and prestrained workpiece material, which requires a sample to be subjected to elastic strain under load not exceeding the proportionality limit of the workpiece material. That is, when the load is removed, the dimensions of the workpiece remain unchanged. The paper presents the experimental device designed to determine the axial force and torque when drilling holes in the stress-strain workpiece material. Multi-factor experiments were carried out to obtain empirical dependences of the axial force and torque arising in drilling holes in the stress-strain workpiecematerial on the process parameters.

Research on Electrical Discharge Machining for Injection Mold of Automotive Connector

2012 ◽  
Vol 522 ◽  
pp. 17-20
Author(s):  
Wei Min Pan ◽  
Ke Ke Shi ◽  
Xian Qing Lei
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Injection Mold ◽  
Workpiece Material ◽  
Electrode Tool ◽  
Mating Surface ◽  
Plastic Components

Electrical discharge machining (EDM) processing is generally applied on the area of molding plastic component or mating surface required high accuracy. The areas determine the quality of the plastic components. The principle of EDM is based on the material vaporization of high potential difference across the workpiece and Tool electrode. Tool electrode and workpieces are discontiguous when the EDM processes. Because there is no mechanical contact, Hardness and strength of the workpiece material have minimal effect on the material removal rate .The application of EDM technology on injection mold of automotive connector is focused on in this paper. Processing of the complex cores is researched. The design and processing of the tool electrode have been completed in the meantime.

scholarly journals Study on the Influence of Metallic Powder in Near-Dry Electric Discharge Machining

2020 ◽  
Vol 66 (4) ◽  
pp. 243-253 ◽  
Author(s):  
Sanjay Sundriyal ◽  
Vipin ◽  
Ravinderjit Singh Walia
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Metallic Powder ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
En 31 ◽  
Edm Process ◽  
Dry Electrical Discharge Machining

Near-dry electrical discharge machining (ND-EDM) is an eco-friendly process. In this study, an approach has been made to make the machining process more efficient than ND-EDM with the addition of metallic powder with the dielectric medium to machine EN-31 die steel. Powdermixed near-dry EDM (PMND-EDM) has several advantages over the ND-EDM or conventional electrical discharge machining (EDM) process, such as a higher material removal rate (MRR), fine surface finish (Ra), sharp cutting edge, lesser recast layer, and lower deposition of debris. The output response variables are MRR, Ra, residual stress (RS) and micro-hardness (MH) of the machined surfaces. Further study of the workpiece was performed, and a comparative study was conducted between ND-EDM and PMND-EDM. In this proposed method of machining, the MRR, Ra, and MH increased by 17.85 %, 16.36 %, and 62.69 % while RS was reduced by 56.09 %.

Technological Innovations in Machining of Inconel 718

2015 ◽  
Vol 5 (2) ◽  
pp. 17-43
Author(s):  
Vivek Aggarwal ◽  
Rajiv K Garg ◽  
Sehijpal Singh Khangura
Keyword(s):  
Inconel 718 ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Machining Performance ◽  
Drilling Operations ◽  
Machining Operations ◽  
Alternative Energies ◽  
Insight Into

In this paper, a thorough review has been presented on the latest research work carried out for the enhancement of machining performance of one of the most commonly used superalloys that is, Inconel 718. The thermal energy has been frequently utilized for improving machinability characteristics of Inconel 718. The review of available literature indicates that plasma, laser, and electric discharge have been the major sources used for the enhancement of tool life, material removal rate, surface integrity, and reduction of cutting forces during machining of Inconel 718. However, a very few efforts have been made as regards to the use of wire electrical discharge machining and other energies like mechanical, electrochemical, and chemical for machining of this material. Moreover, the reported work on machining of Inconel 718 is largely focused on drilling operations. There is ample scope for research work on various other machining operations using alternative energies to gain more insight into machining of Inconel 718 and other similar superalloys.

Removal of Defective Layer after Electrical Discharge Machining

2019 ◽  
Vol 973 ◽  
pp. 157-160
Author(s):  
Stanislav A. Mozgov ◽  
Yuriy A. Morgunov ◽  
Boris P. Saushkin
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Work Piece ◽  
Machining Parameters ◽  
Electrode Gap ◽  
Machining Time ◽  
Defective Layer

This study investigates the possibility of electrochemical removal of the defective layer formed on the surface of the product after its electrical discharge machining. A set of experiments was conducted in different electrolytes based on aqueous and aqueous-organic solvents. The experiments were to trace the influence of such settings of electrochemical machining as current density, electrolyte pumping speed, electrolyte temperature, and an electrode gap upon both the dynamics of metal removal and surface quality. Morphology of the obtained surface was examined by an Olympus BX-51Microscope. The dynamics of removing material (stock) from the work piece was inspected. Appropriate adjustments were made to the machining parameters during the machining of 65G steels, and a preferred composition was selected for the working medium. A sufficient design for production tools was proposed. Pitting corrosion was discovered on the surface of the samples in all studied modes of electrolysis. It was observed that switching from aqueous electrolyte to aqueous-organic electrolyte gave lower material removal rate and longer machining time accordingly. At the same time, a reduction in surface roughness was visualized, together with smaller pits and lower density of their distribution. The obtained results may be applied in operation design for electrochemical machining of steels with relatively high carbon contents.

Modelling and simulation of ultrasonic-assisted jet electrochemical micro drilling process

2019 ◽  
Vol 233 (12) ◽  
pp. 4199-4212
Author(s):  
Harsha Goel ◽  
Usharani Rath ◽  
Pulak M Pandey
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Modelling And Simulation ◽  
Drilling Process ◽  
Ultrasonic Assisted ◽  
Micro Holes ◽  
Micro Drilling ◽  
Experimental Findings ◽  
Electrolyte Jet

Ultrasonic-assisted jet electrochemical micro drilling is an advanced variant of electrochemical machining to drill micro holes quickly and efficiently. The present article deals with the modelling and simulation of the integration of ultrasonic vibration with the conventional jet electrochemical micro drilling process. Multi-physics-based modelling and simulation approach has been used in the present work. The flow pattern of electrolyte jet was analysed for both jet electrochemical micro drilling and ultrasonic-assisted jet electrochemical micro drilling processes. The simulation results were validated with the previous experimental findings of ultrasonic-assisted jet electrochemical micro drilling process. It was found that the material removal rate (MRR) improved significantly as the ultrasonic wave got superimposed onto the electrolyte jet. In addition to that, voltage and concentration of the electrolyte also played vital roles in improving the MRR.

scholarly journals About transition processes in blasthole drilling at quarries

2020 ◽  
Vol 177 ◽  
pp. 01008
Author(s):  
Andrey Regotunov ◽  
Rudolf Sukhov ◽  
Gennady Bersenyov
Keyword(s):  
Rock Properties ◽  
Repair System ◽  
Drilling Process ◽  
Transition Processes ◽  
Material Resources ◽  
Drilling Performance ◽  
Drilling Method ◽  
Drilling Technology ◽  
Drilling Operations ◽  
Main Transition

As a system, the mining enterprise develops under constantly changing conditions of the external and internal environment. These conditions affect the state of the most important drilling subsystem: blasthole drilling technology, safety, performance, power consumption of the boring rigs and roller bits used. The main transition processes as necessary responses of the subsystem to changing conditions were identified as a result of fragmentary data analysis showing decisions taken over the past 15-20 years, which increase drilling activity efficiency and safety of smaller quarries of Russia, which contain a significant amount of material resources. The main transition processes contribute to the growth of drilling performance and consist of changing the following: bit design for specific rocks; drilling method; drilling mode; boring rig design; controlled parameters of drilling process and rock properties redetermination; parameters of maintenance and repair system. Based on the performed analysis, the systematization results of the main factors predetermining the need for transition processes implementation in the “drilling operations” subsystem were obtained and presented. The proposed approach allowed to reveal a holistic picture of the main interacting factors in the “drilling operations” subsystem. Based on the factors systematization presented in the article it is possible to envisage changes of individual factors depending on changes of other factors, not functionally related directly when planning drilling operations.

Electric Discharge Machining of Cryo-Treated NiTi Alloys

2015 ◽  
Vol 787 ◽  
pp. 366-370 ◽  
Author(s):  
Vaibhav Gaikwad ◽  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Workpiece Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Conventional Machining

NiTi alloys possess superior material properties such as high specific strength, high corrosion resistance, high wear resistance and high anti-fatigue property. Due to these properties it is difficult to machine these alloys using conventional machining process. Nowadays non-conventional machining processes are widely used for machining such adavanced materials. Electrical Discharge machining (EDM) is one such non-conventional process, which can machine electrically conductive materials of any hardness values. Present study aims at drilling mesoscale 3 mm square holes on NiTi alloy by varying the electrical parameters namely, gap current, pulse on time and pulse off time. Additional, the present work includes finding out the effect of cryogenic treatment of NiTi work material on electrical discharge machining performance measures namely material removal rate (MRR) and tool wear rate (TWR). Based on experiments conducted, it can be concluded that with increase in current both material removal rate and tool wear rate increases. It is also noted that cryo-treatment of workpiece material improves MRR with respect to gap current. Similarly there is an increase in MRR with respect to pulse on time and pulse off time for cryo-treated workpiece material. There is a slight improvement of TWR with respect to gap current, pulse on time and pulse off time for cryo-treated workpiece material.

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