Improving the Performance of EDM through Relief-Angled Tool Designs

Mufti, Nadeem Ahmad; Rafaqat, Madiha; Ahmed, Naveed; Saleem, Muhammad Qaiser; Hussain, Amjad; Al-Ahamri, Abdulrahman M.

doi:10.3390/app10072432

Cited by 17 publications

(11 citation statements)

References 32 publications

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“…In this study, it has been found that non-conventional electrode design offers high MRR with low overcut as compared to the conventional electrode. In the same study, the relief angled designed tools have been reported as the better option to obtain less amount of overcut while machining circular holes in tungsten carbide [ 26 ]. To select the most appropriate electrode design offering high MRR, and low amounts of TWR and overcut, the electrode design with 20 degree can be considered as the common suitable choice.…”

Section: Resultsmentioning

confidence: 99%

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

et al. 2023

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Electric discharge machining is relatively a slow process in terms of machining time and material removal rate. The presence of overcut and the hole taper angle caused by the excessive tool wear are other challenges in the electric discharge machining die-sinking process. The areas of focus to solve these challenges in the performance of electric discharge machines include increasing the rate of material removal, decreasing the rate of tool wear, and reducing the rate of hole taper angle and overcut. Triangular cross-sectional through-holes have been produced in D2 steel through die-sinking electric discharge machining (EDM). Conventionally, the electrode with uniform triangular cross-section throughout the electrode length is used to machine triangular holes. In this study, new designs of electrodes (non-conventional designs) are employed by introducing circular relief angles. For material removal rate (MRR), tool wear rate (TWR), overcut, taper angle, and surface roughness of the machined holes, the machining performance of conventional and unconventional electrode designs is compared. A significant improvement in MRR (32.6% increase) has been achieved by using non-conventional electrode designs. Similarly, the hole quality resulted by non-conventional electrodes is way better than hole quality corresponding to conventional electrode designs, especially in terms of overcut and hole taper angle. A reduction of 20.6% in overcut and a reduction of 72.5% in taper angle can be achieved through newly designed electrodes. Finally, one electrode design has been selected (electrode with 20 degree relief angle) as the most appropriate electrode resulting in better EDM performance in terms of MRR, TWR, overcut, taper angle, and surface roughness of triangular holes.

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Section: Resultsmentioning

confidence: 99%

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

et al. 2023

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“…To reduce the dimensional errors in EDM, researchers attempted to modify the electrode geometry. They employed electrodes with a certain relief angle and observed a reduction in the value of overcut [24]. Liang et al [25] proposed a self-repair method and a profile error compensation method for tool electrode wear to improve processing accuracy.…”

Section: Introductionmentioning

confidence: 99%

A Novel Electrode Front-End Face Design to Improve Geometric Accuracy in Electrical Discharge Machining Process

Wang

Peng

Gunawan

et al. 2023

Metals

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Electrical discharge machining (EDM) is one of the important machining processes to produce mold components. When using the EDM process, surface quality, processing time, accuracy, and electrode cost must be considered. The electrode wear is the main factor that causes error on the geometric accuracy, especially the workpiece corner. Therefore, this study proposes a novel electrode design to improve the geometric accuracy for the EDM process. Firstly, the effect of discharge current, electrode diameter, and depth of cut on the electrode wear and workpiece corner were investigated. Multiple regression and analysis of variant were used to analyze the experiment data. The electrode end-face design with compensation rule and algorithm was established based on the data analysis and error value. Furthermore, a compensated electrode end-face design system with human machine interface, which has a procedure guiding function, was developed. The system can design the electrode end-face for minimizing workpiece corner error and improve geometric accuracy. Finally, cutting experiments were conducted to verify the proposed method, and the results show that the proposed method can effectively enhance the geometric accuracy by around 22~37%.

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“…The enormous demand for tools, tooling, dies, and molds is due to the extensive use of these items in production. How likely a discharge is determined by how easily electricity can be broken down within the spark gap [4,5]. Any point between the two electrodes will experience a more severe electrical breakdown if debris is present.…”

Section: Introductionmentioning

confidence: 99%

EDM Electrode Design and Analysis to Enhance Process Performance

Abbas,

Khleif

2023

Tikrit j. eng. sci.

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Electric discharge machining (EDM) is regarded as one of the most energy-efficient manufacturing processes for exceptionally accurate processing of any electrically conductive material, regardless of mechanical properties. EDM is a non-contact process utilized in various industries, including aerospace, industrial, instruments, molds, dies, and medical tools; also, it is beneficial for hard materials with simple or proficient geometries and shapes. Although EDM is for machining "difficult to machine" metals, such as those used in the mold and die industries, metal properties indicate potential capability in the domain of surface modification due to the electrical spark between the tool and the work material. This paper investigates the machining of Alloy steel X210 by using the most affecting parameters and how electrode angles contribute to responses, as MRR, Electrode wear ratio, and surface finish, which the manufacturing industry uses to make die tools, molds, automotive parts, and other products. Electrodes with angles of 0o and 90o are used to machine workpieces using WEDM (dk7740). Electrode Angle, peak discharge current, pulse-on time, and pulse-off time were controllable parameters in this study. While all other criteria are constant, variables have been studied. The effects of the four aspects on the four variables were statistically analyzed using ANOVA by MINITAB. Regression models for the responses were developed. Regression mathematical models have been developed for Alloy steel X210 workpieces to increase productivity and industry results.

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Improving the Performance of EDM through Relief-Angled Tool Designs

Cited by 17 publications

References 32 publications

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

A Novel Electrode Front-End Face Design to Improve Geometric Accuracy in Electrical Discharge Machining Process

EDM Electrode Design and Analysis to Enhance Process Performance

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