Electrical arc machining: Process capabilities and current research trends

Abstract

Electrical arc machining is the thermal energy-based unconventional machining process, which utilizes energy of arc to melt and vaporize workpiece material. Electrical arc machining has the capability to machine advanced materials such as metal matrix composites, superalloys, and conductive ceramics effectively. The process is considered to be efficient than most of the other unconventional machining processes in terms of the material removal rate. But it has got limitations because it results in a very poor surface finish. Tool wear rate, recast layer formation, surface and subsurface cracks, and geometrical inaccuracy are other limitations up to a certain extent. In this paper, the comprehensive review of research carried out so for in the area of electrical arc machining has been presented. The paper discusses the detailed experimental and theoretical studies done on electrical arc machining to elucidate the effects of various input control factors on different quality characteristics. The paper also contains modeling and optimization studies done so far in electrical arc machining and finally discusses the future research possibilities in the area.

Vibration-assisted electrical arc machining of 10% B4C/Al metal matrix composite

“…Many researchers have employed side flushing for plasma arc breaking. The side flushing sometimes results in trailing discharge crater, 1 the efficient use of MMABM such as imparting vibration to the tool may help to improve MRR as well as surface integrity simultaneously as tool vibration has found to have positive effect on MRR and SR in the present research.…”

“…Metal matrix composites (MMCs) and superalloys belong to a relatively newer class of materials which have become very popular due to their enhanced mechanical and physical properties. 1 Aluminium–boron carbide (Al–B 4 C) MMC is such an advanced material which is very popular in marine, automobile, aerospace and defense industries. Unconventional machining processes (UMPs) are very popular to machine these types of materials.…”

Surface modification of Hastelloy processed by the Cu mixed electric discharge alloying technique

“…The hardness and tensile strength of Hastelloy were measured as 88HRB and 601 MPa, respectively, making it extremely difficult to process in the conventional machining technique [1]. Ultrasonic machining, abrasive-water jet machining, laser beam machining, plasma arc machining and electric discharge machining (EDM) were some of the distinct unconventional processes utilized for cutting tougher materials [2][3][4]. Of the various machining techniques, EDM produces components with high precision and accuracy [5] and is suitable for hybrid processing [6].…”

Modeling and optimization of VEAM of 10% B4C/Al metal matrix composite using ANN-SCA approach

“…EAM is quite similar to electrical discharge machining (EDM) on many aspects such as source of energy supplied, process input parameters and mechanism of material removal. However the EAM is quite efficient as compared to EDM in terms of material removal rate and energy requirements [2].…”

“…Initially BEAM was performed on the workpiece to achieve high MRR, and then milling was performed on the workpiece to achieve smooth surface finish. Shrivastava et al [2] presented comprehensive review of EAM process and concluded that process has immense potential to contribute for present technological demands. Pandey et al [8] developed innovative machining tool known as vibration assisted EAM and performed experimental investigations on Al/B 4 C MMC and concluded that the developed process is much more efficient than conventional EDM.…”