EDM drilling of ultra-high aspect ratio micro holes with insulated tools

Ferraris, Eleonora; Castiglioni, Valeria; Ceyssens, Frederik; Annoni, Massimiliano; Lauwers, Bert; Reynaerts, Dominiek

doi:10.1016/j.cirp.2013.03.115

Cited by 97 publications

(38 citation statements)

References 7 publications

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“…In [31], the analysis of experimental research shows that the crack density is higher at the edge of the hole bottom, which may attest to the occurrence of secondary discharges in the zone. Secondary discharges also cause an excessive wear of the electrode's tip edge [21,[32][33][34].…”

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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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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“…그래핀은 강한 공유 결합을 이루는 2차원 구조체로 단층 그래핀은 0.34 nm의 두께로 매우 얇으며 기계적(탄성계수 ~1.0 TPa, 파괴강도 123 GPa), 열적(5,000 W/m·K) 그리 고 전기적 특성 (200,000 cm 2 /Vs)이 매우 우수하고, 유연성과 투명성을 가진다 [5] . 마이크로 방전가공(Micro-EDM)은 미세가공에 있 어서 가장 중요한 기술이며 전도성을 가진 재료를 경도와 무관하게 가공할 수 있다 [6] . Capacitance(pF) 10,000…”

Section: 서 론 최근 산업 제품의 소형화 추세에 따라 복잡한 형상을 갖는 기계부품의 미세 형상 가공기술에 대 한 관심unclassified

Material properties and machining performance of CNT and Graphene reinforced hybrid alumina composites for micro electrical discharge machining

Sung¹,

Kim

Kang³

2013

Journal of the Korean Society of Manufacturing Process Engineer

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Aluminum Oxide(Al2O3) ceramics are excellent candidates for such applications due to their outstanding mechanical, thermal, and tribological properties. However, they are difficult to machine using conventional mechanical methods. Carbon fillers, such as carbon nanotubes(CNT) and graphene nanoplatelets(GNP)can be dispersed in a ceramic matrix to improve the mechanical and electrical properties. In this study, CNT and Graphene reinforced hybrid ceramic composites were fabricated using the spark plasma sintering method at a temperature of 1,500℃, pressure of 40 MPa, and soaking time of 10min. Besides this, the material properties such as microstructure, crystal structure, hardness, and electrical conductivity were analyzed using FE-SEM, XRD, Vickers, and the 4-point probe method. A micro machining test was carried out to compare the effects of the material properties and the machining performance for CNT and Graphene reinforced ceramic composites.

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“…In addition, for preparing micro-hole with high precision, ultra short pulses is carried out on 304 stainless steel foil with 20 μm thickness [13]. Ferraris et al reported [14] that micro-hole with 0.2 mm diameter and 120 aspect ratio are obtained by electric discharge machining (EDM) about an hour, the processing cycle of micro-hole is long, and Maity et al [15] also fabricated micro-hole by optimization of this method. Besides, Wang et al [16] manufactured array micro-hole on ceramic material by powder injection molding.…”

Section: Introductionmentioning

confidence: 99%

Casting of array micro-holes on Al components

Jin

You

et al. 2015

Int J Adv Manuf Technol

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A novel preparation process of array micro-holes on Al components is proposed. Carbon fibers were chosen as the hole cores in order to prepare array micro-holes in the casting method. Aiming at demonstrating the quality of array micro-holes, the roughness (R a ) of array micro-holes is researched. The results show that array micro-hole obtained has 222 μm diameter, the line spacing of array micro-holes is about 6 mm, the closer pitch of holes on each line is about 2 mm, and the farther pitch of holes on each line is about 4 mm. Metallostatic pressure and surface tension have an important influence on the roughness of array micro-holes. In this experiment, the roughness (R a ) of array micro-holes is about 6.3 μm.

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EDM drilling of ultra-high aspect ratio micro holes with insulated tools

Cited by 97 publications

References 7 publications

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

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

Material properties and machining performance of CNT and Graphene reinforced hybrid alumina composites for micro electrical discharge machining

Casting of array micro-holes on Al components

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