Fluid Dynamics in Electrode Flushing Channel and Electrode-Workpiece Gap During EDM Drilling

Kliuev, Mikhail; Baumgart, Christoph; Wegener, Konrad

doi:10.1016/j.procir.2017.12.058

Cited by 32 publications

(18 citation statements)

References 9 publications

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“…These phenomena lead to high process instability, defects on the internal surface of the holes, holes with poor shape accuracy (in terms of hole taper and hole dilation), excessive tool wear (at the side and the end), and a low machining speed [12,13,14,17,18,19]. In the deep hole drilling process, a high-pressure pump for dielectric flushing (up to 25 MPa) and tube electrodes with inner flushing are used [20]. Flushing should be done in a sufficiently controlled manner.…”

Section: Introductionmentioning

confidence: 99%

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Machno

2019

Materials

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Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their structure. The quality of the holes significantly affects the cooling process of the elements. However, it is challenging to machine materials by conventional methods. When machining a hole with a high aspect ratio, the major problem is effective flushing of the machining area, which can improve the hole’s surface integrity and dimensional accuracy. Consequently, the electro-discharge drilling (EDD) process is good alternative for this application. This paper presents the results of an analysis of the EDD of Inconel 718 alloy. An experiment was conducted to evaluate the impact of process parameters (pulse time, current amplitude, and discharge voltage) on the process’s performance (linear tool wear, taper angle, drilling speed, the hole’s aspect ratio, and surface roughness (Ra and Rz)). The results show that EDD provides us with the possibility to drill holes with an aspect ratio greater than 10:1. The results also demonstrate that holes with an aspect ratio greater than 10:1 and a small taper angle value have a significantly decreased quality of internal surface, especially at the bottom of the hole. This indicates that an insufficient amount of debris is removed from the bottom of the hole.

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Section: Introductionmentioning

confidence: 99%

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Machno

2019

Materials

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“…When using deionized water as working fluid, the bubbles are much smaller, while a single bubble is formed in the oil. Small bubbles move faster and do not significantly interfere with the erosion process [28,40]. In addition, the area proportion of the bubbles in the discharge gap is smaller in deionized water than in oil [28].…”

Section: Significance Of the Working Fluid In The Edm Processmentioning

confidence: 99%

“…The flushing efficiency can depend on the length and the inside shape (single-channel, multi-channel) of the electrode tool [40] and the working fluid's initial pressure [38]. The dielectric fluid's pressure affects the increase in the metal removal rate (MRR) and the reduction of the surface roughness.…”

Section: The Working Fluid Flow Through the Electrode Channel And Thementioning

confidence: 99%

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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“…According to [37], a copper tube electrode is the best choice for the electric discharge deep hole drilling of Inconel 718, which allows one to obtain a high material removal rate and low surface roughness. Additionally, the single-channel electrode provides comparatively better removal rates and a lower electrode wear ratio than multi-channel electrodes [38]. These determine the selection of this kind of tool electrode.…”

Section: Workpiece and Tool Electrode Materialsmentioning

confidence: 99%

Investigation of the Machinability of the Inconel 718 Superalloy during the Electrical Discharge Drilling Process

Machno

2020

Materials

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The properties of the Inconel 718 superalloy are used in the manufacturing of aircraft components; its properties, including high hardness and toughness, cause machining difficulties when using the conventional method. To circumvent this, non-conventional techniques are used, among which electrical discharge machining (EDM) is a good alternative. However, the nature of removing material using the EDM process causes the thermophysical properties of Inconel 718 to hinder its machinability; thus, a more extensive analysis of the influence of these properties on the EDM process, and a machinability analysis of this material in a wider range, using more process parameters, are required. In this study, we investigated the drilling of micro-holes into the Inconel 718 superalloy using the EDM process. An experiment was conducted to evaluate the impact of five process parameters with a wide range of values (open voltage, time of the impulse, current amplitude, the inlet dielectric fluid pressure, and tube electrode rotation) on the process’s performance (drilling speed, linear tool wear, the side gap thickness, and the aspect ratio of holes). The analysis shows that the thermal conductivity of this superalloy significantly influences the effective drilling of holes. The combination of a higher current amplitude (I ≥ 3.99 A) with an extended pulse time (ton ≥ 550 µs) can provide a satisfactory hole accuracy (side gap thickness ≤ 100 µm), homogeneity of the hole entrance edge without re-solidified material, and a depth-to-diameter ratio of about 19. Obtaining a high dimensional shape accuracy of holes has an enormous effect on their usability in the structure of the components in the aviation industry.

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Fluid Dynamics in Electrode Flushing Channel and Electrode-Workpiece Gap During EDM Drilling

Cited by 32 publications

References 9 publications

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

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

Investigation of the Machinability of the Inconel 718 Superalloy during the Electrical Discharge Drilling Process

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