Electrical Discharge Machining with SiC Powder-Mixed Dielectric: An Effective Application in the Machining Process of Hardened 90CrSi Steel

Tran, Thi-Hong; Nguyen, Manh-Cuong; Luu, Anh-Tung; Tam, Do Thi; Quy, Le Thu; Vu, T. T.; Tran, Ngoc-Giang; Do, Thi-Tam; Pi, Vu Ngoc

doi:10.3390/machines8030036

Cited by 27 publications

(11 citation statements)

References 23 publications

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“…The subject of electrical discharge machining (EDM) and wear of a wire tool electrode is not new, but the physical processes that occur during processing are still not sufficiently studied [1][2][3][4]. It is related to the absence of the possibility of visual control over the processes occurring in the discharge gap during EDM especially for large workpieces [5,6].…”

Section: Introductionmentioning

confidence: 99%

Wire Tool Electrode Behavior and Wear under Discharge Pulses

et al. 2020

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This work is devoted to researching the tool electrode behavior and wear under discharge pulses at electrical discharge machining. The experiments were conducted on the workpieces of 12Kh18N10T (AISI 321) chrome-nickel anti-corrosion steel and D16 (AA 2024) duralumin by a 0.25-mm-diameter CuZn35 brass tool in a deionized water medium. The developed diagnostic and monitoring mean based on acoustic emission registered the oscillations accompanying machining at 4–8 kHz. The obtained workpiece and non-profiled tool surfaces were investigated by optical and scanning electron microscopy. Calculated volumetric and mass removal rates showed the difference in the character of wear at roughing and finishing. It was shown that interaction between material components in anti-corrosion steel machining had an explosive character between Zn of brass and Ni of steel at a micron level and formed multiple craters of 30–100 µm. The secondary structure and topology of worn tool surfaces were caused by material sublimation, chemical interaction between material components at high heat (10,000 °C), explosive deposition of the secondary structure. Acoustic diagnostics adequately registered the character of interaction. The observed phenomena at the submicron level and microstructure of the obtained surfaces provide grounding on the nature of material interactions and electrical erosion wear fundamentals.

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Section: Introductionmentioning

confidence: 99%

Wire Tool Electrode Behavior and Wear under Discharge Pulses

et al. 2020

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“…Ishfaq K. et al [ 31 ] studied the potential of nano-graphene powder to upsurge the cutting rate and surface quality in the EDM of Ti alloy. Tran T. H. et al [ 32 ] investigated the main process parameters influencing the surface roughness with SiC powder-mixed EDM of hardened steel. They selected the following PMEDM parameters in their study: pulse time on, pulse time off, powder concentration, pulse current and the server voltage.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

et al. 2022

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Electric discharge machining with a powder mix dielectric is a promising technique to harden a work piece’s surface using electricity with a high energy density. The quality of the electrical discharge-machined surface is related to its surface integrity in which the surface’s roughness, residual stresses, micro hardness and surface micro cracks are some of the major factors. In this research, graphite powder was mixed in a dielectric with a particle size of 20 µm, 30 µm, and 40 µm, with the concentration of the graphite powder ranging from 2 g/L to 4 g/L. Moreover, the peak current and pulse time on were also coupled with an additive of graphite powder to investigate the effect on the surface quality, i.e., the recast layer thickness, micro hardness and crater depth as well as the material removal rate (MRR) and tool wear rate (TWR). A Box–Behnken design was employed to design the experiments and the experimental results revealed that the graphite powder size and concentration coupled with the electrical parameters (peak current and pulse time on) significantly influenced the recast layer thickness, micro hardness, crater size, MRR and TWR. The crater depth and micro hardness were maximized at a higher concentration and particle size, while the recast layer thickness was reduced with a higher gain size.

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“…In yet another work [11], addition of SiC powder in de-ionized water was seen to increase material removal depth. More recently, SiC powder mixed dielectric has been reported to have positive effect in reducing surface roughness for hardened steel [12]. In yet another work employing a different powder material i.e.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

Saleem

Naqvi

Khan

et al. 2021

Int J Adv Manuf Technol

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Review of the available literature on powder mixed electrical discharge machining (PMEDM) indicates, that most of the research has been done for "die sinking machining mode" whereas the "wire cut machining mode" has not received due attention despite being an important process variant. This work employs Silicon Carbide (SiC) powder mixed dielectric uid for machining of AISI D2 in "wire cut" mode with re-circulating molybdenum wire (an economic and chemically stable proposition as tool). The effect of ve process parameters (powder concentration, peak current, pulse on time, nozzle ushing pressure and stand-off distance) have been evaluated on surface roughness, kerf width, material removal rate and wire wear ratio using Taguchi's approach. It is found that for surface roughness, higher current and low to moderate concentration levels (2 to 4g/l) deteriorate surface quality; higher values of pressure and stand-off distance are also seen to adversely affect it. For material removal rate, pulse on time as well as its interactions with powder concentration and current, are statistically signi cant. A higher pulse on with smaller and moderate powder concentrations (2g/l and 4g/l) reduces MRR. For wire wear ratio, current is the sole signi cant factor (PCR of ~ 65%). SEM analysis of the machined workpiece for the maximum MRR condition quanti es recast layer as ~ 19microns. An indirect comparison with the reported values for non-powdered EDM process indicates that for the similar wire (molybdenum), the use of SiC powder maintains the surface roughness and kerf values, for a much harder D2 material used in this work.

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Electrical Discharge Machining with SiC Powder-Mixed Dielectric: An Effective Application in the Machining Process of Hardened 90CrSi Steel

Cited by 27 publications

References 23 publications

Wire Tool Electrode Behavior and Wear under Discharge Pulses

Wire Tool Electrode Behavior and Wear under Discharge Pulses

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

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