Effect of slotted electrodes on improvement in machining performance of large-scale electrical discharge machining

Lo, Jie; Jiang, Chang Tai; Wu, Kun Ling

doi:10.1177/0954405417752528

Cited by 7 publications

(5 citation statements)

References 25 publications

(33 reference statements)

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“…However, the forming accuracy of porous electrodes is poor, leaving a large margin for subsequent processing, and the process is more complicated. Jie-Shing Lo et al [12] investigated the use of slotted electrodes to improve machining debris removal and compared the machining capability of such electrodes with that of nonslotted electrodes. Compared with general nonslotted electrodes, the deep slotted electrodes improved the material removal rate on large-scale and hemisphere electrical discharge machining result by 91% and 116.7%, respectively.…”

Section: Introductionmentioning

confidence: 99%

Adaptive flushing technology for slotted electrode EDM based on gap discharge status detection

Gao,

Liu,

Han

et al. 2023

Second International Conference on Advanced Manufacturing Technology and Manufacturing Systems (ICAMTMS 2023)

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Traditional Electrical Discharge Machining (EDM) with internal flushing is often used for machining special-shaped cavities of conductive materials, which improves the machining efficiency but tends to produce sizeable residual material columns on the bottom surface of the workpiece cavity, affecting the machining quality. We propose an adaptive flushing technology for slotted electrode EDM based on gap discharge status detection to solve this problem. An adaptive flushing system was built, and the system’s feasibility was verified through experiments. EDM comparison experiments were designed to study the machining performance of the adaptive flushing slotted electrode EDM system. The experimental results show that the Material Removal Rate (MRR) is increased by about 1.1% and 8.0% when using adaptive flushing compared to continuous flushing and no flushing, respectively. The electrode wear rate (EWR) is reduced by about 38.8% and 4.4% compared to continuous flushing and no flushing, respectively. Therefore, adaptive flushing achieves the dual goal of ensuring processing efficiency and reducing electrode wear.

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Section: Introductionmentioning

confidence: 99%

Adaptive flushing technology for slotted electrode EDM based on gap discharge status detection

Gao,

Liu,

Han

et al. 2023

Second International Conference on Advanced Manufacturing Technology and Manufacturing Systems (ICAMTMS 2023)

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“…They found that the fourslotted electrode can provide optimal EDM efficiency and that using slotted electrodes significantly reduces the electrode wear rate. Jie-Shing Lo et al [24] investigated the use of slotted electrodes to improve the removal of erosion products. They analyzed the waveforms of machining voltage and current signals to gain the electrical discharge condition of EDM.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Machining Characteristics in Electrical Discharge Machining Using a Slotted Electrode with Internal Flushing

Gao,

Liu,

Han

et al. 2023

Micromachines

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In die-sinking electrical discharge machining (EDM), it is challenging to implement internal flushing, mainly because it is easy to produce residual material columns on the workpiece cavity’s bottom surface, affecting the processing quality and efficiency. In order to solve this problem, the internal flushing slotted electrode EDM technology was proposed. The slotted electrode was designed, and its preparation method was described. The influence of pulse width, pulse interval, and flushing pressure on the performance of the internal flushing slotted electrode EDM was studied using single-factor experiments. The experimental results indicate that, with the increase in pulse width, the material removal rate (MRR) increases first and then decreases, while the electrode wear rate (EWR) and the relative electrode wear rate (REWR) decrease gradually; with the increase in pulse interval, the MRR decreases, while the EWR and the REWR increase gradually; with the increase in flushing pressure, the MRR increases first and then decreases, while the EWR and the REWR increase gradually. When the slotted electrode is used for continuous internal flushing EDM, the appropriate pulse width, flushing pressure, and smaller pulse interval can improve the MRR and reduce the EWR and the REWR.

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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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Effect of slotted electrodes on improvement in machining performance of large-scale electrical discharge machining

Cited by 7 publications

References 25 publications

Adaptive flushing technology for slotted electrode EDM based on gap discharge status detection

Adaptive flushing technology for slotted electrode EDM based on gap discharge status detection

Investigation of Machining Characteristics in Electrical Discharge Machining Using a Slotted Electrode with Internal Flushing

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

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