Electroplastic cutting influence on power consumption during drilling process

Abstract

The aim of this study is to report the use of non-conventional material removal process technique. It was found that electropulses (EPs) assisted drilling process improves the material machinability based on the eletroplastic influence. The influence of EPs in drilling process is studied by combining different feed rates, drills diameters and current densities in 7075 aluminium and 1045 carbon steel. The results show that the electrically assisted drilling process improves material machinability, decreases the specific cutting energy up to 27% in aluminium and 17% in steel.

Influence of the Regime of Electropulsing-Assisted Machining on the Plastic Deformation of the Layer Being Cut

“…However, the results are in agreement with the previous study [25], in which current density decreases with the increase in cutting feed during electrically assisted drilling process. As the chip formation zone decreases with increase cutting speed, this may be the reason why current density values are higher at high cutting speeds for steel S235 during electrically assisted turning process.…”

“…Hence, due to thermal contribution of EPs, the deformation resistance decreases [31], which ultimately decreases the SCE and improves the plasticity of material during EP assisted turning process. The results are also in agreement with Sánchez et al [24] and Hameed [25] where the SCE decreases due to the application of EPs during machining processes.…”

“…The SCE is the quotient between the cutting power consumption and the material removal rate as described in the previous work [25]. The material removal rate, $Q_c$, is defined by the following equation:$Q_c=V_c·f·a_b\left(1,-,\frac{a_b}{D}\right)$ where $V_c$ is cutting speed (m/min) and D is the workpiece diameter (mm).…”

“…Sanchez et al [24] observed that the SCE and the power consumption are decreased when the turning process is assisted with EPs. In a previous study [25], it was found that, at lower feeds, when the higher current density is induced, the shear angle $\varphi$ decreases and the chip compression ratio $\xi$ increases during drilling process. There was no study or few attempts were made to evaluate the machinability of materials with respect to chip compression ratio $\xi$, shear plane angle $\varphi$ and SCE while cutting with EPs during turning process.…”

Evaluation of an Analytical Model in the Prediction of Machining Temperature of AISI 1045 Steel and AISI 4340 Steel

“…Machining is an important manufacturing methodology because of its precision, fast processing speed, and applicability to a broad class of materials. Conventional machining processes and non-conventional machining processes such as laser-assisted machining [1] and electrically assisted machining [2][3][4] have been widely used to transform bulk materials into products with desired geometry and functionality. Elevated temperature in conventional machining has a negative influence on tool performance, tool life, and the quality of machined parts because it softens tool materials and increases diffusion.…”