A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes †

Yu, Liu; Chang, Hao-Yuan; Zhang, Wenchao; Ma, Fujian; Sha, Zhihua; Zhang, Shengfang

doi:10.3390/mi9080378

Cited by 60 publications

(29 citation statements)

References 16 publications

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“…The same phenomenon related to inter-electrode gap overheating and dielectric thermal decomposition was observed in the second sinking approach. This inaccuracy was eliminated in successive drilling tests by more intense dielectric flushing [16] and electrode tool rotation. The hole remained round and the edge sharp.…”

Section: Resultsmentioning

confidence: 99%

Electrodischarge Drilling of Microholes in c-BN

2020

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Cubic boron nitride (c-BN) is a “difficult-to-cut” material. High precision machining of this material is problematic because it is difficult to control the material removal rate and maintain acceptable accuracy. This paper describes an application of electrodischarge machining (EDM) for drilling micro holes in c-BN. The goal of this research was to determine a set of parameters and technical specifications for such a process. We used an isoenergetic transistor power supply with a microsecond voltage pulse generator and a tungsten tool electrode of diameter d = 381 μm. Each hole was drilled for 10 min. The holes did not exceed 410 μm in diameter and were at least 1000 μm deep. The process was carried out in a hydrocarbon dielectric liquid. We assess the quality of the holes from a qualitative and quantitative point of view. The results show that electrodischarge is a precise, accurate, and efficient method for machining c-BN.

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Section: Resultsmentioning

confidence: 99%

Electrodischarge Drilling of Microholes in c-BN

2020

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“…Consequently, the debris accumulates at the hole bottom leading to the occurrence of abnormal/secondary discharges (such as arc and/or short circuits) between the debris and the sidewall of the hole. In the result, a poor surface quality (increased roughness parameters Ra and Rz), decreased hole accuracy and machining speed, excessive tool wear, decreased gap area occur [14,26,27,29,30]. Abnormal discharges can also occur in the corner of the hole bottom.…”

Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

et al. 2020

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Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of the most effective methods of making high-aspect-ratio holes is electrical discharge drilling (EDD). While drilling high aspect ratio holes, a crucial issue is the flushing of the gap area and the evacuation of the erosion products. The use of deionized water as the dielectric fluid in the EDD offers a considerable potential. This paper includes an analysis of the influence of the machining parameters (pulse time, current amplitude and discharge voltage) on the process performance (drilling speed, linear tool wear, taper angle, hole’s aspect ratio, side gap thickness), during the EDD with the use of deionized water in the Inconel 718 alloy. The obtained through holes were subjected to the extended analysis. The impact of the initial working fluid temperature and pressure on the conditions of the flow through the electrode channel was also subjected to the analysis. The deionized water properties were changed by applying an initial temperature. Based on the results of an analysis of the previous research, the EDD of the through holes was performed for a pre-set initial temperature (~313.15 °K) and initial pressure of the working fluid (8 MPa) and selected process parameters. An analysis of the results indicates increasing of hole’s aspect ratio by about 15% (above 30), decreasing the side gap thickness by about 40% and enhanced surface integrity.

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“…If not taken into attention to the mass of the wire sections h 1 and h 2 and mass losses on electroerosion wear [49,50], an amplitude of oscillation may be presented as a complex amplitude of the harmonic signal [51][52][53]:…”

Section: Mathematical Approach and Evaluation Of Wire Amplitude Undermentioning

confidence: 99%

On Adaptive Control for Electrical Discharge Machining Using Vibroacoustic Emission

et al. 2018

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The article is related to the research of the parameters of vibroacoustic emission for development of the monitoring and adaptive control system for electrical discharge machining. The classical control system based on a response of electrical parameters does not give an adequate data in the cases of a new class of materials processing as conductive ceramics reinforced by conductive nano additives and carbon nanotubes and whiskers. The idle pulses, which are working on the destruction of the erosion products in the gap, count as working pulses. The application of the monitoring and control tools based on vibroacoustic emission gives adequate data about conditions in the working zone. The developed system is available to count only impulses involved in working on the destruction of the workpiece. The experiments were conducted on the samples of materials with a low melting point as austenitic steel and aluminum alloy, and hard alloys. The records of vibroacoustic signals were analyzed for detection of the monitoring and adaptive control criteria.

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A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes †

Cited by 60 publications

References 16 publications

Electrodischarge Drilling of Microholes in c-BN

Electrodischarge Drilling of Microholes in c-BN

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

On Adaptive Control for Electrical Discharge Machining Using Vibroacoustic Emission

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