A gap-active electrical discharge machining (GA-EDM) to rectify the textural defects of the processed surface

Das, Shirsendu; Paul, Swarup; Doloi, B.

doi:10.1016/j.jmapro.2021.01.053

Cited by 10 publications

(5 citation statements)

References 29 publications

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“…The electrode retraction system ensures an adequate passage for flushing, which helps to expel debris and control heat dissipation. Das et al [54] suggested in their study that the gap-active mechanism produced a surface with a better texture and fewer indentations, solidified agglomerates and cracks compared with normal EDM. The use of the secondary dielectric also increased the carbon content in the dielectric and resulted in a surface that was 10-14% harder than that produced using normal EDM.…”

Section: Evolution Of Edm Applicationsmentioning

confidence: 99%

“…Simple metallization techniques have been used, such as electroless plating and electroplating. Conversely, at extreme frequencies, the pulse on-time is inadequate to produce a meaningful discharge [54]. The study in [53] suggested that the pulse on-time was insufficient at higher frequencies to trigger a successful discharge.…”

Section: Effects Of Powder Metallurgy Electrodes In Edm Applicationsmentioning

confidence: 99%

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A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Garba,

Abdul-Rani,

Yunus

et al. 2023

Machines

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In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted.

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Section: Evolution Of Edm Applicationsmentioning

confidence: 99%

Section: Effects Of Powder Metallurgy Electrodes In Edm Applicationsmentioning

confidence: 99%

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Garba,

Abdul-Rani,

Yunus

et al. 2023

Machines

View full text Add to dashboard Cite

show abstract

“…In TOPSIS, the first part is to change the outcomes to a decision matrix comprising of output responses (attributes) in columns and exploratory trials (alternatives) in rows as delineated in Equation (9). By utilizing Equation (10), the decision matrix is normalized, and relative weightage is doled to all entities.…”

Section: Topsis Optimizationmentioning

confidence: 99%

“…To accomplish green and healthy production, save resources, reduce the number of experimental trails, and improve the efficiency of experimental work, CuSn CLEs were employed [8]. Gap-active EDM is another methodology which gives a gap-detectable and automatic adjustable electrode retraction set up to facilitate improved textual attribute with reduced indentation, solidified-agglomerates, and crack [9]. Selecting permissible dielectric fluid is additionally indispensable in EDM since it has influence on the surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Comparative Study on EDM Parameter Optimization for Adsorbed Si₃N₄–TiN using TOPSIS and GRA Coupled with TLBO Algorithm

Srinivasan¹,

Sandeep²,

Shanthi³

et al. 2022

Adsorption Science & Technology

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Electrical discharge machining is a thermo-physical-based material removal technique. 25 combinations of process variables were formulated with the aid of Taguchi technique for EDM of adsorbed Si3N4–TiN. Machining variables like pulse current, pulse-on time, pulse-off time, dielectric pressure, and spark gap voltage varied, and impact of each variables on the performance metrics (MRR, EWR, SR, ROC, θ, CIR, and CYL) was assessed. MCDM strategies like grey relational analysis and TOPSIS are utilized to find out the ideal arrangement of machining parameters to achieve most acute productivity of the multitude of reactions. Likewise, metaheuristic algorithm in particular GRA combined with teaching-learning-based optimization algorithm is utilized for getting global optimized input factors. Important factors like pulse current, pulse-on time, and spark gap voltage characteristically affect the outputs. It is recognized that the pulse-on time and the pulse current are the most significant input factors than others. The ideal machining parameters in view of GRA and TOPSIS techniques for acquiring better output factors are I, 12 amps; PON, 7 μsec; POFF, 4 μsec; DP, 12 kg/cm2; and SV, 36 volts.

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“…The volume of metal removed per discharge of single pulse was calculated by measuring the number of discharges and MRR at different pulse shapes to understand the reason for improvement in MRR [21]. A gap-active EDM (GA-EDM), a concept based on the principle of operation of parallel plate capacitor, was used to evaluate the performance of EDM of Ti6Al4V titanium alloy using copper electrode [22]. Low MRR and better surface finish was observed from their investigation in all discharge levels.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Material Removal Rate and Surface Finish in Electrical Discharge Machining of AA 6061-B4C Composite Material

Ethiraj¹,

Sivabalan²,

Chatterjee³

et al. 2021

JUSST

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One of the non-conventional techniques of metal removal manufacturing processes is electrical discharge machining (EDM). The objective of this paper is to prepare a composite material consisting of a matrix of Aluminium AA 6061 alloy and Boron carbide (B4C) as reinforcement and investigate the output responses, the material removal rate, the quality of the surface formed and overcut during EDM process. The process parameters discharge current, Pulse on time and Duty cycle along with the weight % of B4C are considered for investigation to investigate the output responses such as material removal rate, surface roughness and overcut. From the experimental results, it is observed that the weight % of reinforcement has more influence on the material removal rate. The parameters discharge current and pulse-on-time plays an important role in reducing the surface roughness and overcut. Microstructural study helps in understanding the effect of process parameters on the output responses.

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A gap-active electrical discharge machining (GA-EDM) to rectify the textural defects of the processed surface

Cited by 10 publications

References 29 publications

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Comparative Study on EDM Parameter Optimization for Adsorbed Si₃N₄–TiN using TOPSIS and GRA Coupled with TLBO Algorithm

Investigation on Material Removal Rate and Surface Finish in Electrical Discharge Machining of AA 6061-B4C Composite Material

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A gap-active electrical discharge machining (GA-EDM) to rectify the textural defects of the processed surface

Cited by 10 publications

References 29 publications

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Comparative Study on EDM Parameter Optimization for Adsorbed Si3N4–TiN using TOPSIS and GRA Coupled with TLBO Algorithm

Investigation on Material Removal Rate and Surface Finish in Electrical Discharge Machining of AA 6061-B4C Composite Material

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Comparative Study on EDM Parameter Optimization for Adsorbed Si₃N₄–TiN using TOPSIS and GRA Coupled with TLBO Algorithm