Investigating and removing the re-sticky debris on tungsten carbide in electrical discharge machining

Chou, Shih-Hsien; Wang, A-Cheng

doi:10.1007/s00170-013-5556-y

Cited by 12 publications

(4 citation statements)

References 19 publications

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“…The provision of tool rotation can reduce the amount of debris sticking to the work surface as reported by Chou et al [22]. Yadav et al [23] assessed the effectiveness of EDM by including oxygen into the dielectric and by utilizing the rotary electrode.…”

Section: Introductionmentioning

confidence: 99%

Enhancing Electric Discharge Machining Performance by Selecting Electrode Design and Geometrical Parameters for Square, Triangular, and Hexagonal Profiled Holes

Rafaqat,

Mufti,

Saleem

et al. 2023

Processes

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Manufacturing of dies, molds, and their allied components requires the machining of holes with different profiles. Electric discharge machining (EDM) die-sinking is a crucial process used in the dies and molds manufacturing industry. By nature, EDM die-sinking is a relatively slow process in terms of material removal rate (MRR) and there are high amounts of tool material loss in terms of tool wear rate (TWR) which directly influence dimensional accuracies and surface roughness (SR). Therefore, the process is continuously evolving to address these limitations. The present research is aligned in this direction such as to bring improvements in MRR, TWR, and SR through modifications to the conventional electrode design and its geometrical parameters. Traditional designs of EDM electrodes have a uniform cross-section through the tool’s entire length and have only one geometrical parameter, i.e., the tool’s cross-section. To improve the EDM performance, traditional designs are completely modified by introducing several geometrical parameters such as relief angles, land thickness, cross-sectional area, shank height, circular relief, and non-circular relief, etc. Electrode designs are employed to mill non-circular profiles including triangular, square, and hexagonal shaped holes. The EDM performance measures strongly depend on the tool’s geometrical parameters (design type, relief angle, land thickness), machining profile (circular, square, triangle, hexagon), as well as the height/depth of the machining feature. By selecting proper tool designs and corresponding geometrical parameters, the EDM performance measures can be improved significantly.

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Section: Introductionmentioning

confidence: 99%

Enhancing Electric Discharge Machining Performance by Selecting Electrode Design and Geometrical Parameters for Square, Triangular, and Hexagonal Profiled Holes

Rafaqat,

Mufti,

Saleem

et al. 2023

Processes

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show abstract

“…To overcome this difficulty many researchers provided the rotary motion to the tool to facilitate the expulsion of melt debris [27] and the associated phenomenon is termed as self-flushing [28]. Chou et al [29] reported that resticking of the melt debris on the machined surface is soundly observed when WC is machined through EDM. Provision of tool rotation has soundly overcome the restick problem of debris.…”

Section: Introductionmentioning

confidence: 99%

“…Elemental composition of tungsten carbide. Properties of tungsten carbide (mechanical, thermal, and electrical)[7,8,29]. Electrodes and electric discharge machining (EDM) parameters (constants).…”

mentioning

confidence: 99%

Improving the Performance of EDM through Relief-Angled Tool Designs

et al. 2020

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Among the family of carbides, tungsten carbide (WC) and its variants have extensive use in numerous applications including cutting tools, dies, and many wear resistant parts. Such applications need machining of WC, which is famously considered as challenging due to high tool wear mainly in traditional machining. Sinking electric discharge machining (EDM) can be considered as a suitable alternate but the low machining rate of EDM, with conventional tool design, poses limitations. In this research, the conventional tool design is modified by providing relief angles to the tool electrodes. The relief-angled tool electrodes are first time introduced in this research to machine through holes. The role of the relief angle during EDM has been investigated in terms of six response characteristics, i.e., machining time, hole taper angle, radial overcut at the hole entrance, radial undercut at the hole exit, longitudinal tool wear, and roughness of inside hole surfaces. The performance of the relief-angled electrodes is found to be significantly better than the performance of conventional cylindrical tool. In addition to improvements in other responses, a 49% reduction in the machining time has been realized by the use of relief-angled electrode indicating a worthwhile contribution in the field of electric discharge machining.

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“…They have designed two adaptive neuro-fuzzy inference system models to correlate the EDM parameters to MRR and SR using the data generated based on experimental observations. Then they used continuous ant colony optimization (CACO) technique to select the best process parameters for maximum MRR and specified SR. Chou and wang [10] investigated the re-sticky phenomenon of tungsten carbide and techniques to reduce the debris re-sticking on the workpiece surface. Wang et al [11] studied a novel compound machining of titanium alloy (Ti6Al4V) by super high speed electrical discharge machining milling and arc machining.…”

Section: Introductionmentioning

confidence: 99%

Magnetic Field Assisted Electrical Discharge Machining of AISI 4140

Walkar

Jatti

Singh

2014

AMM

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Electric discharge machining (EDM) is a non-conventional machining process in which material removal take place by a series of electric spark generated between the small gap of both electrode and both immersed in dielectric medium. The gap conditions of EDM significntly affect the stability of machining process. Thus, the machining performance would be improved by removing the debris from the machining gap fastly. In view of this, the objective of present work was to investigate the effect of magnetic field on the material removal rate (MRR) and surface roughness (SR), in conjunction with the variation of electrical parameters like pulse on-off times and gap current, while keeping other electrical parameters and work piece/ tool material constant. Experimental results showed that the magnetic field assisted EDM improves the process stability. Moreover, the EDM process with high efficiency and quality of machined parts could fulfill the requirements of modern manufacturing industries.

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Investigating and removing the re-sticky debris on tungsten carbide in electrical discharge machining

Cited by 12 publications

References 19 publications

Enhancing Electric Discharge Machining Performance by Selecting Electrode Design and Geometrical Parameters for Square, Triangular, and Hexagonal Profiled Holes

Enhancing Electric Discharge Machining Performance by Selecting Electrode Design and Geometrical Parameters for Square, Triangular, and Hexagonal Profiled Holes

Improving the Performance of EDM through Relief-Angled Tool Designs

Magnetic Field Assisted Electrical Discharge Machining of AISI 4140

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