Enhanced surface integrity and dimensional accuracy by simultaneous micro-ED/EC milling

Nguyen, Minh Dang; Rahman, Mustafizur; Wong, Yoke San

doi:10.1016/j.cirp.2012.03.011

Cited by 62 publications

(23 citation statements)

References 6 publications

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“…Electrochemical discharge machining gives possibility to improve efficiency of process and accuracy and quality of surface of holes [9]. One can state that hole machined with = 20 has more regular shape and higher diameter and also is deeper (Fig.…”

Section: Analysis Of Resultsmentioning

confidence: 99%

The Experimental Research of Electrodischarge Drilling of X5CrNi18-10 Stainless Steel

Machno¹,

Bizon²,

Skoczypiec³

2016

The Publications of the MultiScience - XXX. MicroCAD International Scientific Conference

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One of the most important trends in manufacturing technology deals with the miniaturization of products and components. Microelements must be shaped with high accuracy and high surface quality what is difficult when machining of new materials such as stainless steel, titanium alloy, ceramics, especially by traditional machining. In this paper presents EDM drilling of high aspect-ratio holes in X5CrNi18-10 stainless steel. In article has been described the analysis of electrocdischarge drilling with used deionized water as dielectric fluid. The experiment involves the impact of selected parameters as current amplitude, discharge voltage and pulse time on the following technological parameters: hole depth and side gap, linear tool wear and mean drilling speed.

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Section: Analysis Of Resultsmentioning

confidence: 99%

The Experimental Research of Electrodischarge Drilling of X5CrNi18-10 Stainless Steel

Machno¹,

Bizon²,

Skoczypiec³

2016

The Publications of the MultiScience - XXX. MicroCAD International Scientific Conference

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“…The transformation of electrical energy into thermal energy leads to the vaporization and melting of the material of the workpiece and of the tool electrode [13][14][15]. Due to the presence of high temperature (about 10,000 • K) in the machining zone, the quality of the machined surface is unsatisfactory because of the occurrence of erosion micro-craters, re-solidified material, heat affected zone and white layer (recast layer) involving micro-cracks and residual tensile stresses [16][17][18]. A disadvantage of the process is also a low material removal rate and high tool wear reaching above 50% [19].…”

Section: Electrical Discharge Drilling Process (Edd)mentioning

confidence: 99%

“…In electrical discharge machining, the application of deionized water as dielectric fluid indicates considerable potential since it can be treated as slightly conductive electrolyte, and electrodischarge erosion is accompanied by electrochemical dissolution [16,42]. The reaction of electrochemical dissolutions is possible due to resistivity of deionized water ranging widely between 0.1 and 10 MΩ cm based on its purity [43].…”

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

“…The electrochemical dissolution improves the process performance (the maximum material removal rate in deionized water can be about 2.5 to 3 times faster) and reduces the tool electrode wear (the tool wear can be reduced up to 96%), in comparison to the application of oil-based dielectric [45]. The electrochemical reaction also enhances the quality of the machined surface by removing erosion micro-craters and re-solidified material on the rim [16,42]. After the EDM with the use of deionized water, micro-parts with a surface roughness parameter of Ra = 22 nm [16] and Ra = 12-43 nm were obtained [43].…”

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

“…The electrochemical reaction also enhances the quality of the machined surface by removing erosion micro-craters and re-solidified material on the rim [16,42]. After the EDM with the use of deionized water, micro-parts with a surface roughness parameter of Ra = 22 nm [16] and Ra = 12-43 nm were obtained [43]. Additionally, an analysis of the results of the EDM with the use of deionized water in the Inconel 718 alloy shows that the recast layer thickness can be reduced to the average thickness of 3-8 µm [18].…”

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

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Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

et al. 2020

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Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of the most effective methods of making high-aspect-ratio holes is electrical discharge drilling (EDD). While drilling high aspect ratio holes, a crucial issue is the flushing of the gap area and the evacuation of the erosion products. The use of deionized water as the dielectric fluid in the EDD offers a considerable potential. This paper includes an analysis of the influence of the machining parameters (pulse time, current amplitude and discharge voltage) on the process performance (drilling speed, linear tool wear, taper angle, hole’s aspect ratio, side gap thickness), during the EDD with the use of deionized water in the Inconel 718 alloy. The obtained through holes were subjected to the extended analysis. The impact of the initial working fluid temperature and pressure on the conditions of the flow through the electrode channel was also subjected to the analysis. The deionized water properties were changed by applying an initial temperature. Based on the results of an analysis of the previous research, the EDD of the through holes was performed for a pre-set initial temperature (~313.15 °K) and initial pressure of the working fluid (8 MPa) and selected process parameters. An analysis of the results indicates increasing of hole’s aspect ratio by about 15% (above 30), decreasing the side gap thickness by about 40% and enhanced surface integrity.

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Combined Variant of Hybrid Micromachining Processes

Bhowmik

Zindani

2019

Hybrid Micro-Machining Processes

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Enhanced surface integrity and dimensional accuracy by simultaneous micro-ED/EC milling

Cited by 62 publications

References 6 publications

The Experimental Research of Electrodischarge Drilling of X5CrNi18-10 Stainless Steel

The Experimental Research of Electrodischarge Drilling of X5CrNi18-10 Stainless Steel

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

Combined Variant of Hybrid Micromachining Processes

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