Experimental investigation of spark generation in electrochemical discharge machining of non-conducting materials

Jiang, Baoyang; Lan, Shuhuai; Ni, Jun; Zhang, Zhaoyang

doi:10.1016/j.jmatprotec.2013.12.005

Cited by 86 publications

(44 citation statements)

References 19 publications

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“…Since the sparking location distribution around the tool is not uniform and depends on the current density around the tool surface, sparking must be occurred more frequently near the tool edges (rim of the tool bottom). These areas have higher current density compared to the other parts of the tool surface [19]. Consequently tool wear must be more intense along the tool rim.…”

Section: Resultsmentioning

confidence: 99%

Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

Behroozfar

Razfar

2015

Materials and Manufacturing Processes

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Electrochemical discharge machining is a nonconventional machining method which can be used to machine nonconductive materials such as glass and ceramics. However, machining of the refractory materials such as ceramics requires high voltages to produce the required thermal energy. In this condition, the tool wear would be increased significantly. This paper reports the study of the wear of the different tool materials. The selected tool materials have different melting/boiling temperatures responding to the high voltages in different ways. The possibility of using different tool materials in high voltages along with estimation of tool surface temperature are discussed in this paper.

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Section: Resultsmentioning

confidence: 99%

Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

Behroozfar

Razfar

2015

Materials and Manufacturing Processes

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“…A customized DC power supply with provision for varying frequency and duty ratio was used for the experiments. Workpiece used was a borosilicate glass of dimension 200mm x 50mm x 5mm 8 An experiment was conducted using Plackett-Burman design. This design is widely accepted for conducting preliminary experiments.…”

Section: Methodsmentioning

confidence: 99%

“…The ratio of the crater depth (H) to the crater diameter (D) for ECDM is in the range 0.2-0.3 [8]. Assuming that, the average diameter of the crust is approximately equal to the radius of curvature (R) of the spherical crater.…”

Section: Model For Surface Roughnessmentioning

confidence: 99%

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

Ladeesh

Manu

2017

MATEC Web Conf.

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Abstract. Grinding aided electrochemical discharge machining is a hybrid technique, which combines the grinding action of an abrasive tool and thermal effects of electrochemical discharges to remove material from the workpiece for producing complex contours. The present study focuses on developing fluidic channels on borosilicate glass using G-ECDM and attempts to develop a mathematical model for surface roughness of the machined channel. Preliminary experiments are conducted to study the effect of machining parameters on surface roughness. Voltage, duty factor, frequency and tool feed rate are identified as the significant factors for controlling surface roughness of the channels produced by G-ECDM. A mathematical model was developed for surface roughness by considering the grinding action and thermal effects of electrochemical discharges in material removal. Experiments are conducted to validate the model and the results obtained are in good agreement with that predicted by the model.

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“…Optimization of the material removal rate and prediction of the surface roughness of the ceramic workpiece were the main outputs of their study. Jiang et al [21] proposed an empirical approach to find the electrical power of the discharges generated in ECDM process. According to their results, the mean spark energy of 3.8 mJ was obtained.…”

Section: Introductionmentioning

confidence: 99%

“…Also the location of each spark is not predictable. However, it is shown by Jiang et al[21] that sparking is concentrated around the rims and edges of the tool. It may be due to the higher current density in these regions.…”

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confidence: 98%

Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

Behroozfar

Razfar

2015

Materials and Manufacturing Processes

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In this paper a novel approach is proposed to investigate the characteristics of the plasma channel and material removal in electrochemical discharge machining (ECDM) of glass.For this purpose, a specific pulsed voltage was applied to the ECDM process to perform single discharging on the glass workpiece. In this way, a voltage slightly lower than the critical voltage was applied as the offset voltage. Meanwhile the working voltages above the critical voltage were applied to the process in a specific period of time to produce single sparks. The signatures of the single sparks on the workpiece surface were used to determine the characteristics of the plasma channel. According to the results, the average diameter of 260 µm was achieved for the plasma channel in the glass machining conditions. This paper also reports a thermo-physical model for material removal in ECDM process based on the finite element method (FEM) and plasma channel diameter achieved in this study. The amount of the removed material as well as the diameter and depth of the crater, achieved by the FEM, was measured and compared with the experimental outcomes. The results demonstrate the consistency of the proposed model with the experimental observations.

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Experimental investigation of spark generation in electrochemical discharge machining of non-conducting materials

Cited by 86 publications

References 19 publications

Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

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