Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

Behroozfar, Ali; Razfar, Mohammad Reza

doi:10.1080/10426914.2015.1004685

Cited by 87 publications

(32 citation statements)

References 20 publications

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“…The auxiliary electrode (anode) was a stainless steel 304L block of size 100×50×10 mm and the cathode was a tapered-tip WC tool with diameter of 500 µm. The reason for using WC as the tool material was its high resistance against the tool wear in the glass machining voltages [8]. Also Soda-lime glass slides of size 75×25×1 mm were used as the workpiece and two DC power supplies (0-60 V, 0-5 A) were employed to apply the required working and offset voltages.…”

Section: Methodsmentioning

confidence: 99%

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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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Section: Methodsmentioning

confidence: 99%

“…ECDM process can be employed to machine hard, brittle and nonconductive materials in a reasonable time and cost with acceptable aspect ratio and low damages to the workpiece [4][5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

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

Behroozfar

Razfar

2015

Materials and Manufacturing Processes

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“…Hajian et al [14] investigated effects of magnetic field orientation on ECDM performance and concluded that magnetic field orientation increased channel depth and surface quality. Behroozfar and Razfar studied characteristics on the plasma channel and material removal [15] and tool wear [16] during ECDM. Dhanvijay and Ahuja [17] studied machining parameters of stagnant and electrolyte flow method on ECDM and obtained the results that electrolyte flow method had a high MRR but a high diametric overcut that had been minimized.…”

Section: Ecdmmentioning

confidence: 99%

Electrochemical discharge machining: A review

Özmen¹,

Asiltürk²

2016

IJSEA

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In this study, progress and sort of electrochemical discharge machining (ECDM) that was developed to manufacture the micro features like micro grooves, micro pillar, micro holes and micro channels etc. were investigated. Many materials can be machined regardless of material conductivity, hardness and strength by ECDM using electro chemical machining (ECM) and electric discharge machining (EDM) combination. Researchers developed electrochemical discharge drilling (ECDD), turning (ECDT), grinding (ECDG), milling, dressing, trepanning, wire ECDM, die-sinking ECDM, rotary ECDM, powder mixed ECDM, magnetic field assisted ECDM, vibration assisted ECDM methods. Pyrex, glass, stainless steel, cermet, soda lime glass, quartz, silicon nitride, zirconium oxide, borosilicate glass, diamond crystals, e-glass/epoxy composite, kevlar/epoxy composite and silicon wafer were used as a work piece. Effects of machining voltage and drilling depth on mean diameter, influence of tool travel rate on groove width and depth and effects of voltage types on micro holes accuracy and machining type etc were investigated. This review is to discuss the results of studies and applicability of this methods. It sums up also with a vision for future research in electrochemical micromachining.

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“…The vibration assistance to the electrolyte improved the spark stability by ensuring the availability of electrolyte at the machining zone throughout the process. Cheng et al [20] applied a magnetohydrodynamic convection (MHD) to enhance the electrolyte circulation, thereby preventing the deterioration of gas film quality with the increase in machining depth. The technique reduced the machining time and improved the entrance diameter of the holes produced.…”

Section: Introductionmentioning

confidence: 99%

“…The use of maintaining tool as anode increased the rate of cutting quartz, but produced significant tool wear. As an attempt to study the tool wear mechanisms in ECDM, Ali et al [20] conducted experiments using different tool materials under different conditions. They reported that the tool wear mechanism depends upon the tool material composition and the tungsten was identified as the most suitable material for high-voltage application.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

Ladeesh

Manu

2018

J Braz. Soc. Mech. Sci. Eng.

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Machining of advanced glass ceramics is of great importance and is a challenging task for the modern industries. In this study, a new hybrid technique of grinding-aided electrochemical discharge drilling (G-ECDD) is attempted which combines the grinding action of a rotating abrasive tool and thermal melting action of electrochemical discharges to perform drilling of borosilicate glass. G-ECDD is performed using a normal electrochemical discharge machine setup with a provision for using a rotating diamond-coated drill tool. The tool used is a hollow diamond core drill rather than the traditional solid abrasive tool. A spring-fed tool system was designed and developed to provide the tool-feed movement which will also help to maintain a balance between grinding action of diamond grits and thermal melting action of discharges. Preliminary experiments are conducted to identify the optimum spring force of the spring-fed system and tool rotational speed which can facilitate a balanced ECDM and grinding action for material removal. The effect of machining parameters like voltage, duty ratio, pulse cycle time and electrolyte concentration on material removal rate (MRR) and hole radial overcut (ROC) is investigated using response surface methodology (RSM). Duty ratio and voltage are found to be the most significant factors contributing MRR. Voltage and pulse cycle time are identified as the main factors controlling radial overcut of the drilled holes. Second-order regression models for MRR and ROC are developed using the data collected from the experiments using RSM. Grey relational analysis was used to optimize this multi-objective problem. A voltage of 90 V, duty ratio of 0.7, cycle time of 0.002 s and an electrolyte concentration of 3.5 M are found to be the best combination for optimizing the responses. Deterioration of bonding material and dislodging of diamond grits are found to be the major modes of tool wear during G-ECDD. The use of high-frequency pulsed DC increased the tool wear rate due to the less time available for heat dissipation between discharge cycles. Moreover, the wear at the end face of the tool will be accelerated due to the concentration of current density at edges during high-frequency operation. From the microscopic images of the machined surface, the material removal mechanisms involved in G-ECDD are found to be a combination of thermal melting by discharges, grinding action of diamond grits and high-temperature chemical etching effect of the electrolyte.

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Experimental Study of the Tool Wear During the Electrochemical Discharge Machining

Cited by 87 publications

References 20 publications

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

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

Electrochemical discharge machining: A review

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

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