Electrode wear phenomenon and its compensation in micro electrical discharge milling: A review

Kar, Siddhartha; Patowari, Promod Kumar

doi:10.1080/10426914.2018.1453144

Cited by 41 publications

(7 citation statements)

References 243 publications

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“…Electric pulses of high frequency pass through the space between the wire electrode and workpiece, and discharge sparks. The material removal occurs by this spark discharges ahead of the moving wire electrode [5, 10, 11, 12].…”

Section: Introductionmentioning

confidence: 99%

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Pramanik

Basak

Prakash

2019

Heliyon

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Non-conventional machining process for instance, wire electrical discharge machining (WEDM) of titanium alloys is gaining attention due to non-contact nature of this process. To deepen the understanding in this area, this study investigates surface generation, kerf width, discharge gap, material removal rate and wire degradation during WEDM of Ti6Al4V alloy. Pulse on time (4–10 μs), flushing pressure (7–18 MPa) and wire tension (800–1700 gf) were varied and resulting influences on output parameters were analysed. It was found that, machined surfaces consist of multi-layered recast layer with the presence of cracks, holes as well as traces of materials from electrode wire. The composition and roughness of the machined surface varies slightly with respect to machining condition without following any trend. In addition, deformation and morphology of deformed wire electrode after the WEDM process was also reported in this study.

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Section: Introductionmentioning

confidence: 99%

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Pramanik

Basak

Prakash

2019

Heliyon

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“…These quantities are recorded in order to be used as tool wear and material removal predictors since they are highly correlated to the wear of the tool electrode. This has been demonstrated by numerous experimental and theoretical studies in literature, for instance references [17,[25][26][27][28]. The values of f p , v f , and u are computed using an averaging window corresponding to steps of 50 µm in drilling depth, similarly to what was done in [17,29].…”

Section: Data Collectionmentioning

confidence: 95%

Tool Wear and Material Removal Predictions in Micro-EDM Drilling: Advantages of Data-Driven Approaches

Bellotti

Qian

et al. 2020

Applied Sciences

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In micro electrical discharge drilling, regression models are commonly used for predicting the material removal rate (MRR) and tool wear rate (TWR) from the applied processing parameters. However, these models can be inaccurate since the processing parameters might not always be representative of the actual machining conditions, which depend on several other factors such as the tool length or gap flushing efficiency. In order to increase the prediction accuracy, the present work investigates the capability of data-driven regression models for tool wear and material removal prediction. The errors in predicting the MRR and TWR are shown to decrease of about 65% and 85% respectively when using data collected through process monitoring as input of the regression models. Data-driven approaches for in-process tool wear prediction have also been implemented in drilling experiments, demonstrating that a more accurate control of the hole depth (50% average reduction of the depth error) can be achieved by using data-driven predictive models.

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“…The thermal characteristics of the electrodes influence the surface morphology in the EDM process [22]. The tool wear of the electrode can also influence the surface morphology of the specimen in the process [23,24]. The physical characteristics of the electrode in the process could alter the quality measures of the machining process in the machining engineering specimen.…”

Section: Introductionmentioning

confidence: 99%

Influence of Adaptive Gap Control Mechanism and Tool Electrodes on Machining Titanium (Ti-6Al-4V) Alloy in EDM Process

et al. 2022

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Titanium alloy is widely used for orthodontic technology and easily machined using the EDM process. In the EDM process, the workpiece and tool electrode must be separated by a continuous air gap during the machining operation to generate discharge energy in this method. In the present study, an endeavor was made to analyze the effects of a servo feed air gap control and tool electrode in the EDM process. The developed mechanical setup consists of a linear action movement with zero backlash along the X-axis, which can be controlled up to 0.03 mm. It was observed that the suggested air gap control scheme can enhance the servo feed mechanism on a machining titanium alloy. A tungsten carbide electrode can enhance the surface measures owing to its ability to produce tiny craters with uniform distribution. Since it produces a little crater and has a higher melting point, a tungsten carbide electrode can create lesser surface roughness than a copper tool and brass tool electrode.

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Electrode wear phenomenon and its compensation in micro electrical discharge milling: A review

Cited by 41 publications

References 243 publications

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Tool Wear and Material Removal Predictions in Micro-EDM Drilling: Advantages of Data-Driven Approaches

Influence of Adaptive Gap Control Mechanism and Tool Electrodes on Machining Titanium (Ti-6Al-4V) Alloy in EDM Process

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