Micro-electrical discharge machining of difficult-to-machine materials: A review

Prakash, Ved; Kumar, P. Sreenivasa; Singh, PK; Hussain, Manowar; Das, Alok Kumar; Chattopadhyaya, Somnath

doi:10.1177/0954405417718591

Cited by 85 publications

(47 citation statements)

References 89 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…The electrical energy was converted to thermal energy by means of a series of discrete electrical discharges between the electrode and workpiece immersed in dielectric medium. 7–9 Due to the sparking effect, the energy distributed over all the regions of the surface. 10,11 During EDM modification procedures, the discharge characteristics and energy distribution of the working medium play an important role in the microstructure and properties modification of strengthened layer.…”

Section: Introductionmentioning

confidence: 99%

Research on discharge characteristics of working mediums of electric discharge machining

Liu

Zhao

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Successful surface modification can be obtained by Electrical Discharge Machining (EDM). In this work the discharge characteristics in misted deionized water and near-dry powder-mixed medium was studied systematically, as well as the microstructure and properties of electrical discharge strengthened layers on TC4 alloy. It indicates that the breakdown voltage of EDM in misted deionized water medium has been reduced to about 1/3 than in air medium. In near-dry powder-mixed medium, it is reduced to about 1/9, because the discharge gap is much larger than that of other mediums. In other words, a stable discharge can be obtained by larger discharge gaps and lower pulse energy than traditional EDM surface strengthening method, which leads to more stable discharge process. Experimental researches show that dense and sound combination with matrix like, multiphase hybrid intensification and chrysanthemum petal-like microstructure of strengthened layers can be observed in the near-dry powder-mixed medium. Meanwhile, it is found that the microhardness of the strengthened layer is up to about 1200 HV, which is four times higher than the base material.

show abstract

Section: Introductionmentioning

confidence: 99%

Research on discharge characteristics of working mediums of electric discharge machining

Liu

Zhao

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Muthuramalingam 32 analyzed the influence of a modified pulse energy generator system on performance measures and observed that peak current is a significant factor in determining white layer formation in the EDM process. An advanced review of conventional- and micro-EDM of difficult-to-machine materials, such as nickel and its alloys, titanium alloys, stainless steel (SUS 304), and advanced ceramics, has been presented by Prakash et al 33 Rajeswari and Shunmugam 34 presented a comparative study on the performance of the classical EDM and powder-mixed and ultrasonic-assisted rough die-sinking EDM based on pulse characteristics. Mascaraque-Ramirez and Franco 35 worked on different methods for experimental analysis of surface integrity in die-sinking and suggested that the crater diameter can be adopted as a better indicator to characterize the surface quality in EDM.…”

Section: Introductionmentioning

confidence: 99%

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

Eyerci̇oğlu

Göv

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

This study presents an experimental investigation of small hole electrical discharge machining of Al-Mg-Ti alloys. A series of drilling operations were carried out for exploring the effect of magnesium content. Holes of 2 mm diameter and 15 mm depth were drilled using tubular single-hole rotary brass electrodes. The rates of material removal and electrode wear, surface roughness, overcut, average recast layer thickness, taper height and angle were studied for Al-Mg-Ti alloys contain 2%, 4%, 6%, 8%, 10%, 12%, and 14% Mg. The results show that the material removal rate is increasing with increasing Mg content while the rate of electrode wear is almost unchanged. Due to decreasing the melting temperature of the Al-Mg-Ti alloy with increasing Mg content, more metal melts and vaporizes during electrical discharge machining drilling. Therefore, more overcut and taper, thicker white layer, and rougher surfaces were measured for higher Mg content.

show abstract

“…In particular, micro-electrical discharge machining (EDM) and micro-electrochemical machining (ECM) have been have been extensively researched for the micromachining of Inconel 718. 7,8 However, these technologies are limited by the challenges of severe electrode wear, low machining speed, and increased cost. Ultrasonic-assisted hybrid machining (USM) is considered as an alternative process for the fabrication of Inconel 718.…”

Section: Introductionmentioning

confidence: 99%

Investigation on laser-induced oxidation assisted micro-milling of Inconel 718

Xia

Zhao

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Poor surface quality and rapid tool wear are the main problems in micro-cutting of Inconel 718. In this study, a novel hybrid machining method named laser-induced oxidation assisted micro-milling is proposed to solve the aforementioned problems. A loose oxide layer and a relatively flat sublayer are formed on the material after laser irradiation. Under optimized laser parameters with a scanning speed of 1 mm/s and an average laser power of 4.5 W, the thicknesses of the oxide layer and the sublayer are 24 and 18 μm, respectively. The influence of cutting parameters on milling force, surface roughness, surface quality, and top burr size is studied in detail. Cutting force and thrust force in the proposed hybrid machining process are lower than those in the conventional micro-milling. Results show that for the investigated range of parameters, the optimal feed per tooth and depth of cut in the hybrid process are 3 μm/z and 3 μm, respectively. When using the optimal parameters, the surface roughness of the machined slot bottom is 108.5 nm. The top burr size on the up-milling side and the down-milling side is 26.8 and 36.2 μm, respectively. In addition, the tool wear mechanism is coating delamination in hybrid process, whereas chipping, coating delamination, tool nose breakage, and adhesion are the main tool wear mechanism in the conventional micro-milling. For the same amount of material removal, the proposed hybrid process can decrease the tool wear and enhance the service life of the micro-end mill as compared to conventional micro-milling.

show abstract

Micro-electrical discharge machining of difficult-to-machine materials: A review

Cited by 85 publications

References 89 publications

Research on discharge characteristics of working mediums of electric discharge machining

Research on discharge characteristics of working mediums of electric discharge machining

The effect of magnesium content on drilling of Al-Mg-Ti alloy by hole electrical discharge machining process

Investigation on laser-induced oxidation assisted micro-milling of Inconel 718

Contact Info

Product

Resources

About