Assessing the effects of different dielectrics on environmentally conscious powder-mixed EDM of difficult-to-machine material (WC-Co)

Singh, Jagdeep; Sharma, Rajiv Kumar

doi:10.1007/s11465-016-0388-8

Cited by 34 publications

(19 citation statements)

References 32 publications

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“…However, the tool wear was different and up to four times lower than steel. Singh and Sharma (2016) [153] carried out an experimental investigation on the powder mixed EDM of cobalt-bonded tungsten carbide (WC-Co). The tool diameter was 17 mm and made of electrolytic copper.…”

Section: Edm Of Non-conductive Ceramicsmentioning

confidence: 99%

Electro-Discharge Machining of Ceramics: A Review

et al. 2018

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Conventional machining techniques of ceramics such as milling, drilling, and turning experience high cutting forces as well as extensive tool wear. Nevertheless, non-contact processes such as laser machining and electro-discharge machining (EDM) remain suitable options for machining ceramics materials, which are considered as extremely brittle and hard-to-machine. Considering the importance of ceramic machining, this paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved. This study also presents a concise literature review of experimental and theoretical research studies conducted on the EDM of ceramics. Finally, a section summarizing the major challenges, proposed solutions, and suggestions for future research directions has been included at the end of the paper.

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Section: Edm Of Non-conductive Ceramicsmentioning

confidence: 99%

Electro-Discharge Machining of Ceramics: A Review

et al. 2018

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“…The effect of different powder concentration of graphite powder on responses such as Ra, TWR and MRR on H-11 die steel was studied, revealing that the addition of graphite powder at a concentration of 6 g/l enhances the MRR and surface finish while tool wear rate is decreased [5]. Research was conducted with different dielectrics on environmental and hazard and operability (HAZOP) analysis in PM-EDM, concluding that HAZOP analysis successfully reduced the wastage of dielectric, and minimized the machining cost and environmental hazards as compared to traditional EDM machining methods [6]. The thermal phenomenon in powder-mixed near-dry electrical discharge machining (PMND-EDM) was explained, and the tendency of variation in MRR was analysed by varying each process parameter [7] to [9].…”

Section: Introductionmentioning

confidence: 99%

Study on the Influence of Metallic Powder in Near-Dry Electric Discharge Machining

Sundriyal

Vipin

Walia

2020

SV-JME

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Near-dry electrical discharge machining (ND-EDM) is an eco-friendly process. In this study, an approach has been made to make the machining process more efficient than ND-EDM with the addition of metallic powder with the dielectric medium to machine EN-31 die steel. Powdermixed near-dry EDM (PMND-EDM) has several advantages over the ND-EDM or conventional electrical discharge machining (EDM) process, such as a higher material removal rate (MRR), fine surface finish (Ra), sharp cutting edge, lesser recast layer, and lower deposition of debris. The output response variables are MRR, Ra, residual stress (RS) and micro-hardness (MH) of the machined surfaces. Further study of the workpiece was performed, and a comparative study was conducted between ND-EDM and PMND-EDM. In this proposed method of machining, the MRR, Ra, and MH increased by 17.85 %, 16.36 %, and 62.69 % while RS was reduced by 56.09 %. Highlights • Experimental investigations have been conducted in the PMND-EDM process. The metallic powder (zinc) as an additive alongwith the mist of a dielectric medium was used for performance enhancements. • In PMND-EDM, the MRR was influenced by powder concentration. The MRR increases with the increase in metallic powder concentration, and the maximum increase in MRR was 17.85 %, as compared to ND-EDM. • The surface finish was improved by 16.36 % in PMND-EDM as the sparking is uniformly distributed among the powder particles, which gives even and uniform machined surfaces. • There was a decrease in residual stress by 56.09 % over the machined surfaces in PMND-EDM as compared to ND-EDM process. • The maximum increase in MH was 62.69 % over the machined surface in PMND-EDM as compared to ND-EDM.

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“…The interaction between Co-based binders and WC grains on early stages of liquid-phase sintering can be strongly affected by the carbon content in the binders [2]. Tungsten cemented carbide (WC-Co) has a series of excellent properties, such as hardness, strength, toughness, wear resistance, and corrosion resistance [3,4].…”

Section: Introductionmentioning

confidence: 99%

Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool

Huang

Sheu

2020

Micromachines

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Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15.

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Assessing the effects of different dielectrics on environmentally conscious powder-mixed EDM of difficult-to-machine material (WC-Co)

Cited by 34 publications

References 32 publications

Electro-Discharge Machining of Ceramics: A Review

Electro-Discharge Machining of Ceramics: A Review

Study on the Influence of Metallic Powder in Near-Dry Electric Discharge Machining

Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool

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