Effects of non-electrical parameters on the characteristics of discharge craters and machining performance in short electrical arc milling

Wang, Bingbing; Zhou, Jianping; Chen, Xiaokang; Xu, Yan; Tang, Wei; Qin, Caoyang; J, Yu

doi:10.1177/09544062231171033

Cited by 3 publications

(1 citation statement)

References 22 publications

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“…The surface texture after machining consists of overlapping spherical craters created by a single electrical discharge. Local microstructure changes occur in the surface texture due to the impact of local thermal processes [32,33]. The shape and depth of the craters directly affect the surface roughness of the workpiece and strictly depend on the technological parameters of EDM, which determine the amount of material removed from the crater during a single electric discharge.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Milling performance of Ti2AlNb by DC short electric arc machining based on different electrode materials

Yin

Zhou

Chen

et al. 2023

Int J Adv Manuf Technol

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In this paper, a novel e cient and sustainable electrical discharge machining method, referred to as short electric arc machining (SEAM), is proposed to solve the problems of low e ciency, severe tool wear, and high cost of Ti2AlNb machining by traditional methods. The mechanism of SEAM with different voltages and tool electrode materials (W70Cu30, high-purity graphite, copper-plated graphite, and 304 stainless steel) is studied using a DC power supply, and the workpiece material removal rate (MRR), surface roughness (Sa), and relative tool wear rate (RTWR) are analyzed. In addition, the surface morphology, cross-sectional morphology, elemental distribution, and microhardness of Ti2AlNb after processing are investigated. The experimental results show that under 28 V, the W70Cu30 electrode achieves the highest MRR of 2571 mm 3 /min, which is higher than that of the other three electrode materials. It has also the lowest RTWR of the electrode and a relative electrode loss of only 0.0974%. The lowest surface roughness and heat affected layer of the workpiece after machining are 53.2 µm and 56.54 µm, respectively. The absolute difference of the width of the cross-section of the workpiece is the smallest, and the hardness of the recast layer of the workpiece is close to the hardness of the base metal, which is conducive to further processing. the thickness of the workpiece heat affected layer after machining with copper-plated graphite and 304 stainless steel electrodes is 64.6 µm and 72.4 µm, respectively.(5) The EDS analysis shows that after SEAM, a large amount of carbon, oxygen, and metal elements adheres to the workpiece surface, which indicates that after carburization and oxidation of the workpiece material, the tool electrode material and the conductive medium occur. The surface hardness of the workpiece machined by both high-purity graphite and copper-plated graphite electrodes signi cantly increases. Finally, the hardness values gradually decrease with the increase of the surface depth.

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Effect of short electric arc milling discharge machining on the processing performance of two-dimensional C/SiC composites

Wang,

Zhou,

et al. 2024

Int J Adv Manuf Technol

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Effects of non-electrical parameters on the characteristics of discharge craters and machining performance in short electrical arc milling

Cited by 3 publications

References 22 publications

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Milling performance of Ti2AlNb by DC short electric arc machining based on different electrode materials

Effect of short electric arc milling discharge machining on the processing performance of two-dimensional C/SiC composites

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