New EDM Generator Used for the Machining of 1.2363 and 1.2343ESR Steels

The basic building block of any electric discharge machine is a generator, which ensures the operation of material separation itself. Not only the erosion rate and electricity consumption but also the quality of the machined surfaces depend on the design of the generator. These key factors for efficient machining have been investigated using a new energy-saving and powerful generator developed for the electric discharge machine (EDM) while machining 1.2363 and 1.2343ESR steels. In order to monitor and model the responses in the form of eroding rate and surface quality, a two-level half-factor experiment was performed with one replication at the corner points and two replications at the central points, for a total of 80 rounds. Both graphite and copper electrodes of sizes 10x10 mm and 100x100 mm were used for eroding and the influence of parameter settings: Open-voltage, Pulse current, Pulse on-time and Pulse off-time was monitored. It was found out that the shape of the electrode and Pulse current have the most significant effect on the erosion rate. The parameters Pulse current, Pulse on-time and their mutual interaction have the most significant effect on the surface topography. Statistically significant factors influencing the occurrence of defects turned out to be Pulse current, Pulse on-time and Material of workpiece, where it can be seen that the material 1.2343ESR is significantly less prone to the formation of surface defects.

Modelling and optimization of energy intensity of an electrical discharge machine

Nowadays, high fabrication productivity and high-quality products are a matter of course. However, it would not be possible without the use of highly sophisticated progressive technologies in the production process. But many of these modern production technologies are characterized by high consumption of energy. Given the current energy prices, this is not an insignificant amount of money. It is also necessary to point out, that in many cases the rule concerning the mutual interconnection of the energy intensity of production technologies with the resulting quality of the machined area applies. These reasons led us to the optimization of energy consumption in the context of the required quality of the machined surface in terms of selected indicators. The paper aims to describe the results of the performed experimental measurements in order to create mathematical models with subsequent optimization of electricity consumption of an electrical discharge machine. Unlike many types of research conducted in the field so far, the results of the solution were based on determining the relationships between the energy intensity of the electrical discharge machine and its controllable outputs in terms of the final roughness of the eroded surface. The performed optimization based on experimentally obtained results was directed so that its results could be applied in real conditions of technical practice.

Formation and Optimization of Electrical Discharge Coatings Using Conventional Electrodes

An emerging topic is electrical discharge (ED) coating with its application on complex shapes and cavities to repair components or act as functional coatings. Because it is a variant process of an electric discharge machine (EDM) with the ability to coat on electrically conductive substrates, there is a possibility that next-generation electrical discharge machining components may exploit the attachment phenomenon to enhance recast layer properties. Previously, researchers have obtained ED coating by mixing the powder in a dielectric medium and/or by using powder metallurgy electrodes. In this work, primarily, an insight in the formation of ED coating on-die sinks electrical discharge machine, using conventional electrode materials viz., bronze on titanium alloy (Ti-6Al-4V) is made. The bronze electrode on the titanium substrate obtained a crack-free copper coating of ~20 microns thickness. In order to perform the experiments, three combinations were made using five parameters: current (Amps), ton (µs), Toff (µs), duty cycle (%), and flushing pressure as constant (bar). After obtaining the coating, a combination of input parameters was selected by optimizing the output performance parameters, viz., the electrical discharge deposition rate, coating thickness, micro-cracks, and elemental coating composition. Secondarily, different optimization techniques viz., grey relational analysis, the technique for order of preferences by similarity to ideal solution, −nD angle method and information divergence method were implemented to find out the suitable combination of parameters where the latter two methods were introduced for the first time in this area of EDM optimization. A study was conducted to check whether the latter two methods are optimization techniques or multi-criteria decision-making techniques. The optimization of existing reactor types and the development of new reactors in wastewater treatment through EDC, by which energy could be saved by replacing the conventional techniques.

A review on the effect of using rotary hyflex electrical discharge machining endodontic files on the formation of dentinal microcracks in straight root canals

Endodontic therapy is based on cleaning and shaping the canal system till the apex with total obturation of the canal. However, it is not always straightforward. Endodontics specialists face many complicated cases as sever curved canals, calcified canals and canals with previously initiated therapy which require to deal with. dental professionals pay attention to create new methods or to improve the already developed equipment and procedures to facilitate their work. Rotary endodontics files are in the center of attention. nowadays, recent files with extraordinary properties have been revolutionized. The standard Nickel Titanium rotary endodontic files are not always preferred. It cannot serve well in the aforementioned complex cases due to its larger tapers and unique shape memory property. Moreover, these files have led to several dentinal microcracks formation during canal preparation using the flaring instruments. Microcracks are evaluated through the accurately presented sliced images using Micro-Computer Tomography (micro-CT) done before and after root canal preparation. This has led to the invention of new generations of rotary endodontics files, with unique properties improving its behavior during the instrumentation, including Controlled Memory (CM) files and Electrical discharge Machine (EDM) files, opening the door for a new era in the field of endodontics dentistry. The present study aims to review HyFlex EDM files, including their properties, clinical dental usage, and the role of micro-CT in analyzing dentinal micro cracks formed with HyFlex EDM files.

Effect of Input Parameters on SR and MRR for Tool Steel AISI L2 By Electric Discharge Machine (EDM)

Electric discharge machine (EDM) or may be call electric spark machine is one of the most important cutting process or manufacturing process because it gives high accurate dimension and can be produced the most complex shape. In this present material removal rate and surface roughness for tool steel AISI L2 studied. The input parametric for this process is current, pulse on time (Ton) and pulse off time (Toff).A full factorial method is used to formulate machine parameters and find the optimal process parameters of an electric spark. The result shows that the Surface roughness increasing with increasing current and pulse on time is increases while no effect by increase in pulse off time. Best surface roughness when using low current and pulse in time. The material removal rate is increasing with increasing in current and pulse on time while decreasing when pulse of time is increased. The experimented and predicted values by using Minilab17 software ​​of this process are approximately equal.