An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

Puthumana, Govindan

doi:10.1515/meceng-2017-0009

Cited by 4 publications

(4 citation statements)

References 35 publications

(76 reference statements)

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“…While increasing the electrode rotational speed slightly improved machining time and accuracy due to better flushing conditions, very high rotational speed was found to be unsuitable for machining accuracy. In the study conducted by Puthumana et al [11] provided valuable insights into the tool wear behaviour in μ-EDM. By using statistical methods and analyzing the effects of capacitance, feed rate, and voltage on the tool wear ratio, they contributed to a better understanding of the machining process and its optimization.…”

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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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 published literature indicate that just few studies have reported on the analysis of minimizing the shape deviation in WEDM by taking into account the electrical discharge parameters [28][29][30][31][32]. Therefore, in this paper, theoretical and experimental investigation of the WEDM condition and parameters like the dielectric volumetric flow Q v , wire tension F n and wire speed on shape deviation for the cut parts was conducted.…”

Section: Introductionmentioning

confidence: 99%

Archives of Metallurgy and Materials

Świercz

Oniszczuk-Świercz

Zawora

et al. 2019

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New materials require the use of advanced technology in manufacturing parts of complex shape. One of the modern nonconventional technology of manufacturing difficult to cut materials is the wire electrical discharge machining (WEDM). The article presents the results of theoretical and experimental research in the influence of the WEDM conditions and parameters on the shape deviation during a rough cut. A numerical model of the dielectric flow in the gap (ANSYS) was developed. The influence of the dielectric velocity field in the gap on the debris evacuation and stability of WEDM process was discussed. Furthermore, response surface methodology (RSM) was used to build empirical models for influence of the wire speed V d , wire tension force F n , the volume flow rate of the dielectric Q v on the flatness deviation after the WEDM.

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“…The tool wear in micro EDM is affected by multiple factors including electric parameters, machining polarity, dielectric fluid, tool electrode shape, materials of the tool electrode and workpiece, and different EDM processes. A lot of research has been carried out on tool wear for achieving a lower wear ratio or/and compensating for the wear [3][4][5][6]. In 2015, Maradia et al found that the carbonaceous build-up on graphite tool electrodes can be obtained as electrode wear protection in meso-micro EDM.…”

Section: Introductionmentioning

confidence: 99%

Servo scanning 3D micro EDM for array micro cavities using on-machine fabricated tool electrodes

Tong

Zhang

2018

J. Micromech. Microeng.

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Array micro cavities are useful in many fields including in micro molds, optical devices, biochips and so on. Array servo scanning micro electro discharge machining (EDM), using array micro electrodes with simple cross-sectional shape, has the advantage of machining complex 3D micro cavities in batches. In this paper, the machining errors caused by offline-fabricated array micro electrodes are analyzed in particular, and then a machining process of array servo scanning micro EDM is proposed by using on-machine fabricated array micro electrodes. The array micro electrodes are fabricated on-machine by combined procedures including wire electro discharge grinding, array reverse copying and electrode end trimming. Nine-array tool electrodes with Φ80 µm diameter and 600 µm length are obtained. Furthermore, the proposed process is verified by several machining experiments for achieving nine-array hexagonal micro cavities with top side length of 300 µm, bottom side length of 150 µm, and depth of 112 µm or 120 µm. In the experiments, a chip hump accumulates on the electrode tips like the built-up edge in mechanical machining under the conditions of brass workpieces, copper electrodes and the dielectric of deionized water. The accumulated hump can be avoided by replacing the water dielectric by an oil dielectric.

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An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

Cited by 4 publications

References 35 publications

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

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

Archives of Metallurgy and Materials

Servo scanning 3D micro EDM for array micro cavities using on-machine fabricated tool electrodes

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