Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite

Yan, Biing Hwa; Wang, Che Chung; Chow, Han Ming; Lin, Yan Cherng

doi:10.1016/s0890-6955(00)00005-5

Cited by 61 publications

(16 citation statements)

References 29 publications

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“…When the workpiece surfaces machined by EDM are compared with the traditionally ground ones, a 15% to 20% reduction in fatigue strength of the work material is found for electrical-discharge-machined surfaces [22]. In the machining of 6061 aluminum alloy and Al 2 O 3 -reinforced metal composite workpieces with rotating round copper tools, a reduction in V W with an increasing amount of Al 2 O 3 is observed [23]. In another study, the diameter of the crater produced by a single discharge on an Al-SiC metal composite workpiece is measured.…”

Section: ) Composite Toolsmentioning

confidence: 99%

An experimental investigation of tool wear in electric discharge machining

Özgedik

Çoğun

2005

Int J Adv Manuf Technol

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In this study, the variations of geometrical tool wear characteristics -namely, edge and front wear -and machining performance outputs -namely, workpiece removal rate, tool wear rate, relative wear and workpiece surface roughness -were investigated with varying machining parameters. Experiments were conducted using steel workpieces and round copper tools with a kerosene dielectric under different dielectric flushing conditions (injection, suction and static), discharge currents and pulse durations. The experiments have shown that machining parameters and dielectric flushing conditions had a large effect on geometric tool wear characteristics and machining performance outputs. Additionally, published research on tool wear is presented in detail in this study. Symbolsh a Front surface wear height (average) (mm) h a Front surface wear rate (mm/min) i e Discharge current (A) r o Outer edge radius (mm) r i Inner edge radius (mm) t e Discharge duration (µs) t i Pulse duration (µs) t m Machining duration (min) t o Pulse interval time (µs) u e Discharge voltage (V) P s Suction flushing pressure (bar) P i Injection flushing pressure (bar) R 2 Regression constant R a

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Section: ) Composite Toolsmentioning

confidence: 99%

An experimental investigation of tool wear in electric discharge machining

Özgedik

Çoğun

2005

Int J Adv Manuf Technol

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“…Electrical Discharge Machining (EDM) has proven itself a capable method for machining a variety of materials [4,8] and was successfully applied in machining titanium [9,10,11,12,13], metal matrix composites [14,15,16,17] as well as ceramic composites [4,18,19,20,21]. The ability of EDM to remove material without application of mechanical force has the possibility of eliminating many of the difficulties seen in conventional machining of composite materials such as drilling.…”

Section: Introductionmentioning

confidence: 99%

“…Either of which will decrease the machining efficiency, as well as decrease the quality of the cut. These defects can be avoided if the energy used for processing is kept low enough; however, this was noted to extend the cutting time [21,22,24,26,27]. In summary, when properly applied, it has been demonstrated that composite materials can be machined using EDM [28].…”

Section: Introductionmentioning

confidence: 99%

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

Spaulding

2016

Materials

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An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application.

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“…Shiou and Cheng [24], studied the effect of ball burnishing parameters on surface finish of a free form surface plastic NAAS Rating: 3.11 injection mould on a machining centre. For burnishing parameters namely the ball material, burnishing speed, feed and force were selected as the experimental factors of Taguchi's design of experiments to determine the optimal burnishing parameters, which have a dominant influence on surface roughness.…”

Section: Surface Parametersmentioning

confidence: 99%

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

Al¹

2018

IJMPERD

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Roller burnishing is one of the surface finishing processes without removing of a material, where a roller rolls over the machined surface under high pressure and flattens, the roughness peaks into valley. It will improve surface finish, as well as enforces favorable compressive residual stresses and raises hardness in functional surfaces. Aluminium alloys find attractive alternate for high strength applications. In this experimental work, burnishing operation is carried out on various Aluminium alloys, such as Al 2014and Al 6063 using different burnishing parameters, such as cutting speed, feed, no of passes and depth of cut using burnishing tool. Through this experimental work, parameter that affects the surface roughness and surface hardness, on Al 2014 and 6063 material was identified and its influence on these responses was discussed.Also, the studies include the application one of the machine learning techniques is fuzzy logic, in the aspects of modeling and optimization of various process parameters applied, with roller burnishing process. This would give the comprehensive idea on choosing an optimum burnishing condition.

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Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite

Cited by 61 publications

References 29 publications

An experimental investigation of tool wear in electric discharge machining

An experimental investigation of tool wear in electric discharge machining

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

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