Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Krupa, Jacob Serah; Samuel, G.L.

doi:10.1177/0954405421995605

Cited by 8 publications

(3 citation statements)

References 19 publications

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“…In this aspect, a simple cylindrical tool is modified to improve flushing and machining performance. Various types of tool geometry used by researcher are foil, 10 slotted, 11,12 stepped, 13 peripheral slots, 14 bunched, 15 tubular, 16 semi-cylindrical, 17 inclined micro-slots, 18 helical slots, 19 single and double-helical, 20 and 3D printed complex profile 21 to improve machining performance. However, all the study was focused on the experimentation to enhance material removal rate and reduce tool wear rate.…”

Section: Introductionmentioning

confidence: 99%

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

Mullya¹,

Karthikeyan

Ganachari³

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In micro-electrical discharge milling (μED-milling), the rotation and forward feed motion of the tool is the key element responsible for evacuation of the debris particles. The inability to eliminate debris from the interelectrode gap (IEG) causes secondary discharge, short-circuit, and hampers removal rate. This problem is predominant in electrical discharge machining (EDM) where the tool is stationary. Various methods have been devised in the literature to boost debris removal from the IEG. In this paper, the use of a slotted tool with different cross-sections is proposed. The dielectric flow-field, debris trajectory, and cooling rate are calculated using computational fluid dynamics (CFD). Effect of different parameters such as tool rotation, gap size, jet velocity, the shape of slots on the dielectric flow is determined. The slots on the tool create turbulence which enhances the debris removal from the IEG. It also provides the space to accumulate the debris particles, thereby increasing the removal rate. The variation in the dielectric flow-field greatly affects the debris flushing from the IEG. The trajectory of the debris particles depends on their initial position in the IEG and they cool rapidly, which is validated using simulation and mathematical approach.

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Section: Introductionmentioning

confidence: 99%

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

Mullya¹,

Karthikeyan

Ganachari³

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…And the double spiral groove tool has better chip breaking performance. 19 Some scholars designed drill bits with stepped geometry and compared them with a conventional drill. It was found that the delamination of the step drills at low feed rates would be reduced, and the thrust and torque were reduced when using step drills.…”

Section: Introductionmentioning

confidence: 99%

Study on machinability of three-step drill in drilling Ti6Al4V

Wu¹,

Wang²,

Dai

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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As the research progresses, titanium alloy materials have more applications in aerospace and other fields. However, problems such as chip winding and serious tool wear are easy to occur in the machining process. In this research, the three-step drill has changed the main cutting-edge structure, which is more conducive to chip breakage. Firstly, the drilling force of the three-step drill bit is analyzed, and the alternating stress that makes the chip thickness change is obtained by the cutting-edge structure of the three-step drill bit. The simulation and experiment are verified by each other, and the feasibility of three-step drilling to improve the processing quality is obtained. The results show that the improved drill has good chip breaking performance, low thrust force, and better machining performance compared with the twist drill. In addition, the improved drill can obtain a more complete inner wall of the hole and reasonably improve the surface quality. Through experiments, it is found that changing cutting parameters such as feed rate has different effects on chip thickness, thrust and tool wear. It was found that the drilling force was reduced by drilling Ti6Al4V material with the three-step drill. Moreover, the three-step drill can produce smaller chip thicknesses and make the chip more prone to breakage when compared with the twist drill. The high wear of three-step drill bits can also be better weakened by coating materials.

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“…Wang et al [10] improve debris evacuation and decreased the tool electrode wear by using a helical tool electrode. Jacob et al [11] successfully fabricated a double helical grooved tool electrode and found that the double helical grooved tool electrode performed better in debris removal than the single helical grooved tool electrode. Moreover, Kumar et al [12] fabricated a series of microinclined slots on the surface of a solid cylindrical tool electrode.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

Gou

Lai²,

Lin³

et al. 2022

Preprint

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The accumulation of debris in the inter-electrode gap caused by inefficient flushing during the micro-electrical discharge machining (micro-EDM) process leads to severe tool electrode wear and decreases the machining accuracy of micro-holes. In this study, a novel method of tool electrode spiral motion feed mode combined with fixed reference axial compensation (FRAC) is proposed to promote the evacuation of debris and improve the machining accuracy of micro-holes. Different depths of micro-holes in titanium alloy are drilled using the tool electrode linear feed mode and tool electrode spiral motion feed mode combined with FRAC and without compensation. The process parameters are optimized and determined by means of response-surface experiments. The results show that the tool electrode spiral motion feed mode can improve the debris evacuation more effectively than the tool electrode linear feed mode. The micro-hole without a cone at the bottom can be fabricated using the tool electrode spiral motion feed mode. The introduction of FRAC method can improve the depth error of micro-holes further. A high accuracy micro-hole with a depth error of only 0.21% can be fabricated efficiently under the optimal process parameters. The tool electrode spiral motion feed mode combined with FRAC has an obvious advantage in the fabrication of high accuracy micro-holes during the micro-EDM process.

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Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Cited by 8 publications

References 19 publications

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

Study on machinability of three-step drill in drilling Ti6Al4V

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

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