Experimental investigation on effects of dielectric mediums in near-dry electric discharge machining

Dhakar, Krishnakant; Dvivedi, Akshay; Dhiman, Amit

doi:10.1007/s12206-016-0425-x

Cited by 38 publications

(14 citation statements)

References 16 publications

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“…Gupta and Gupta (2019) have done a review of the non-conventional machining process and revealed that near dry EDM gives a negligible tool to wear. Moreover, Dhakar et al (2016) proved the same conclusion after the experimental investigation of the near dry EDM process. Kumar and Babu (2016) have studied the near dry WEDM process and infers that it restricts adverse effects on operator an environment.…”

Section: Literature Reviewsupporting

confidence: 67%

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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Purpose Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM). Design/methodology/approach This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining. Findings It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM. Originality/value The range of predicted results and the experimental results are in close agreement, authenticating the model.

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Section: Literature Reviewsupporting

confidence: 67%

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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“…Simulation is conducted with the commercial software ANSYS. According to the research of Krishnakant et al 29 , using gas–liquid two-phase medium as discharge medium can induce the increase of inter-electrode discharge gap. Therefore, the discharge gap ∆ 1 of DMA-DAP constructed in this paper is greater than ∆ 2 of EDM.…”

Section: Resultsmentioning

confidence: 99%

“…At this time, under the dual actions of the discharge channel and the oxidation exothermic high temperature, the water vaporizes rapidly and expands until it explodes, thereby indirectly increasing the discharge power of the products from the inter-electrode corrosion, as shown in Fig. 1 c. The main purpose of the nitrogen or argon in the mixed gas is to reduce the oxygen concentration and control the stability of the ablation process 28 , 29 . Figure 1 d shows the actual machining status of the MA-DAP.…”

Section: Methodsmentioning

confidence: 99%

Experimental investigations into the performance of die-sinking mixed-gas atomization discharge ablation process on titanium alloy

Kong

Lei

Wei

et al. 2022

Sci Rep

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As a variant of highly efficient electrical discharge machining (EDM), the die-sinking mixed-gas atomization discharge ablation process (DMA-DAP) uses an atomized dielectric formed by a mixed gas, which mainly composed of oxygen and supplemented by nitrogen, and water medium as the discharge medium. In this technology, the oxygen in the medium is used for exothermic oxidation, and the vaporization and explosion of the water generates a chip removal force for highly efficient erosion. The present work uses single-factor tests to compare the characteristics of processing the difficult-to-machine material titanium-alloy special-shaped cavities using either DMA-DAP or EDM. The current, pulse width, pulse interval, and dielectric pressure are selected as the single-factor processing parameters, and how they influence the material removal rate (MRR), electrode relative wear rate (ERWR) and the surface morphology of the processed square cavities is analyzed. The results show that with DMA-DAP, the MRR is more than 12 times that of EDM, the ERWR is reduced by more than 98%, and the surface morphology is relatively good. Finally, taking an aero-engine radial diffuser as the profiling object, DMA-DAP realizes a profiling sample in the form of a variable-cross-section cavity that EDM cannot process, and the efficient die-sinking processing ability of DMA-DAP is verified.

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“…While increasing the spark current, the SR is exploiting due to the highest debris by high spark intensity in the plasma channel [61]. The surface roughness is getting reduced by increasing flushing efficiency while increasing flow rate [65,66]. However, SR is also slightly increased by growing MRR by fast flushing debris (Figure 7(c)).…”

Section: 1response Surface Analysis Using Box-behnken Methodsmentioning

confidence: 97%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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Experimental investigation on effects of dielectric mediums in near-dry electric discharge machining

Cited by 38 publications

References 16 publications

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Experimental investigations into the performance of die-sinking mixed-gas atomization discharge ablation process on titanium alloy

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

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