A strategy for low electrode wear in meso–micro-EDM

Maradia, Umang; Knaak, Reto; Busco, Walter Dal; Boccadoro, Marco; Wegener, Konrad

doi:10.1016/j.precisioneng.2015.06.005

Cited by 28 publications

(7 citation statements)

References 22 publications

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“…184 Although, zero-tool wear technologies are being increasingly implemented in conventional EDM for reduced resource consumption and improved process efficiency; they have not yet been developed for micro-EDM operations. 185 For ultrasonic micro-machining, handling of fine abrasive particles and the debris formed during machining, electromagnetic field and audible noise present threats to the operators’ safety. 186…”

Section: Sustainability Issues In Micro-machiningmentioning

confidence: 99%

Micro-machining: An overview (Part II)

Jain

Patel

Ramkumar

et al. 2021

Journal of Micromanufacturing

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This article on ‘Micro-machining: An Overview (Part II)’ is in continuation to ‘Micro-machining: An Overview (Part I)’ published in this journal ( Journal of Micromanufacturing). It consists of four parts, namely, electrochemical micro-texturing, electrochemical spark micro-machining, molecular dynamics simulation and sustainability issues of micro-machining processes. Electrochemical micro-texturing (ECMTex) deals with various techniques developed for micro-texturing on different types of workpiece-surfaces, namely, flat, curved and free-form surfaces. Here, basically two categories of techniques have been reviewed, namely, with mask and without mask. It also deals with ‘single point tool micro-texturing’ which turns out to be a single-step technique requiring minimum time, but the accuracy and repeatability obtained after micro-texturing need to be critically analysed. For mass production, one needs to go for sinking kind of ECMTex processes. Electrochemical spark micro-machining (ECSMM) is an interesting hybrid (ECM+EDM) process which can be applied for electrically conducting as well as electrically non-conducting materials. However, the work reported in this article deals only with the electrically non-conducting materials for which this process was initially developed. This process has a lot of potential for theoretical work to be done. In this article, two theories of sparking/discharging have been briefly mentioned: single bubble discharging/sparking and single surface discharging. It also dicusses its applications for different types of electrically non-conducting materials. Molecular dynamics simulation (MDS) of micro-/nano-machining processes is very important, but it is very cumbersome to understand at atomic/molecular scale. In these processes, the material behaviour at micro-/nano-level machining is completely different as compared to bulk-machining (macro-machining) processes. Hence, some fundamentals of MDS have been discussed. It just gives the idea of available techniques, softwares and models for different types of processes. However, there is the need of further research work to be done for clearly understanding the MDS of micro-/nano-machining. In the end, the sustainability of micro-machining issues have been discussed, mainly based on the energy consumption per unit mass of production. It is concluded that the advanced micro-manufacturing processes are highly energy-intensive processes, and they need further studies to be done for making them more suitable from sustainability point of view. At the end of each section, some potential areas of research for enhancing the accuracy and repeatability, and minimising the production time of each process have been discussed.

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Section: Sustainability Issues In Micro-machiningmentioning

confidence: 99%

Micro-machining: An overview (Part II)

Jain

Patel

Ramkumar

et al. 2021

Journal of Micromanufacturing

View full text Add to dashboard Cite

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“…This is attributed to coalescence of irregularly shaped particles, produced due to thermal spalling on account of smaller tool diameter [75]. Also, use of a hydrocarbon based dielectric at longer pulse duration shows carbon deposition on the tool and workpiece surface [75,76]. This increases brittleness of the workpiece and leads to increase in crack density [75].…”

Section: Electrical Parametersmentioning

confidence: 99%

Microfeatures and microfabrication: current role of micro-electric discharge machining

Singh

Mali

2019

J. Micromech. Microeng.

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The field of microfeatures and microdevices is an emergent field, with applications extending from cooling of turbine blades to drug delivery in the human body. Fabrication of these features, microfabrication, is a challenge as it requires precise control over material removal in the micro domain. There are several techniques available for microfabrication, of which microelectric discharge machining (μ-EDM) has emerged as a leading technique for its versatility on different materials and ability to fabricate intricate parts and features. This paper presents compiled information on microfeatures, their applications, and different microfabrication techniques with emphasis on the current status and role of µ-EDM in microfabrication.

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“…The study contributes to advancements in machining techniques for micro-scale components and provides a novel approach to overcome the limitations of traditional μEDM and μECM processes. Maradia et al [22] investigated the challenges of electrode machining and electrode wear in die-sinking EDM for precision machining of meso-micro-scale features. They demonstrated the machining of micro-scale graphite electrodes and identified the main factors influencing electrode wear.…”

Section: Introductionmentioning

confidence: 99%

Investigation of effect of thickness in micro drilling of Ti-6Al-4V alloy using tungsten copper electrode

Sawant,

Patil

2024

Eng. Res. Express

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The effectiveness and precision of electric discharge machining (EDM) in fabricating holes in challenging materials rely on the careful choice of suitable tools, materials, and process parameters. Nevertheless, the productivity and material removal rate (MRR) of the EDM process impacted by unstable machining conditions and inadequate removal of debris, especially when drilling holes with high aspect ratios. This study focused on examining how various machining conditions influenced the response variables TWR, MRR, and hole taper (HT) were investigated for with different thickness of plates, namely 0.5 mm(W1), 1 mm (W2), and 1.5 mm (W3) of Ti-6Al-4V. The Taguchi based L9 orthogonal array used to design the experiment and the obtained results were subjected to analysis using Analysis of Variance (ANOVA). The effective implementation of appropriate flushing techniques, efficient debris evacuation, and consistent maintenance of machining conditions resulted in enhanced performance for rotary micro EDM (µ-EDM). However, the µ-EDM process is influenced by numerous operating parameters. The findings revealed that the percentage contribution of capacitance and electrode rotation speed (ERS) is more significant compared to voltage. Specifically, for the W3 workpiece, capacitance displayed utmost MRR 0.01894 mm3/min, which is 51.12% and 63.10% greater than the W1 and W2 workpieces respectively. In contrast, the W1 workpiece exhibited the least TWR of 0.000193 mm3/min, which was 50.61% and 67.24% lower than the W2 and W3 workpieces respectively. The W1 workpiece enhanced accuracy as it significantly reduced the HT as compared to the W2 and W3 workpieces. Scanning Electron Microscopy (SEM) was utilized to investigate how workpiece thickness and process parameters influence the surface quality of micro-holes during manufacturing. Through SEM analysis, present study examined the effects of voltage, capacitance, ERS and thickness of the workpiece on the micro-hole surfaces, enabling a deeper understanding of their impact on the final product's quality.

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A strategy for low electrode wear in meso–micro-EDM

Cited by 28 publications

References 22 publications

Micro-machining: An overview (Part II)

Micro-machining: An overview (Part II)

Microfeatures and microfabrication: current role of micro-electric discharge machining

Investigation of effect of thickness in micro drilling of Ti-6Al-4V alloy using tungsten copper electrode

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