Micro‐Electro Discharge Machining (µEDM)

Jahan, Muhammad P.; Asad, Abu Bakar Ali; Rahman, M.; Wong, Yoke San; Masaki, Takeshi

doi:10.1002/9781118010570.ch10

Cited by 12 publications

(4 citation statements)

References 72 publications

(137 reference statements)

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“…Whereas, an increase in the interelectrode gap distance increases the plasma resistance but does not affect the plasma current, thereby, increasing the discharge energy at a fixed open gap voltage. (5) For open gap voltage in the range of 100-300 V and gap distance in the range of 0.5-6 lm, the enhanced model of micro-EDM plasma suggests that a higher open gap voltage and higher interelectrode gap distance can be used to obtain a higher discharge energy, which can lead to a higher MRR [15,[19][20][21][22][23]. Also, the predictions of time-transient discharge power can be used in micro-EDM material removal models [23][24][25][26][27] to estimate the heat flux given to the electrodes during a discharge.…”

Section: Discussionmentioning

confidence: 99%

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Model-Based Prediction of Plasma Resistance, and Discharge Voltage and Current Waveforms in Micro-Electrodischarge Machining

Mujumdar

Curreli

Kapoor

et al. 2015

Journal of Micro and Nano-Manufacturing

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In electrodischarge machining (EDM), the thermal energy causing material removal at the electrodes is given by the electrical energy supplied to the discharge. This electrical energy, also known as the discharge energy, can be obtained from time-transient voltage and current waveforms across the electrodes during a discharge. However, in micro-EDM, the interelectrode gaps are shorter causing the plasma resistance to be significantly smaller than other impedances in the circuit. As a result, the voltage and current waveforms obtained by a direct measurement may include voltage drop across the stray impedances in the circuit and may not accurately represent the exact voltage drop across micro-EDM plasma alone. Therefore, a model-based approach is presented in this paper to predict time-transient electrical characteristics of a micro-EDM discharge, such as plasma resistance, voltage, current, and discharge energy. A global modeling approach is employed to solve equations of mass and energy conservations, dynamics of the plasma growth, and the plasma current equation for obtaining a complete temporal description of the plasma during the discharge duration. The model is validated against single-discharge micro-EDM experiments and then used to study the effect of applied open gap voltage and interelectrode gap distance on the plasma resistance, voltage, current, and discharge energy. For open gap voltage in the range of 100–300 V and gap distance in the range of 0.5–6 μm, the model predicts the use of a higher open gap voltage and a higher gap distance to achieve a higher discharge energy.

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Section: Discussionmentioning

confidence: 99%

“…As a combined result, the discharge energy of micro-EDM plasma is seen to increase with an increase in the open gap voltage when gap distance is held constant. Many experimental studies have shown that a higher discharge energy results in a higher MRR in EDM [15,[19][20][21][22][23].…”

Section: Effect Of Open Gap Voltage and Gap Distance Onmentioning

confidence: 99%

Model-Based Prediction of Plasma Resistance, and Discharge Voltage and Current Waveforms in Micro-Electrodischarge Machining

Mujumdar

Curreli

Kapoor

et al. 2015

Journal of Micro and Nano-Manufacturing

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“…Electrical discharge machining (EDM) is the method of removing electrically conductive materials in the form of small craters ranging from several to tens of microns using strictly coordinated sparks occurring between a tool electrode and a workpiece in the presence of a dielectric fluid [13]. The mechanism of the micro-EDM process is fundamentally the same as the EDM process with the major differences being tool dimensions, discharge energy supplied and the resolution of the axes movement [14].…”

Section: Principle Of Processesmentioning

confidence: 99%

Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview

et al. 2019

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Many of the industrial processes, including material removal operation for shape generation on the surface of material, exploit the assistance of ultrasonic vibrations. This trend of using ultrasonic vibration in order to improve the process performance is becoming more and more prominent recently. One of the significant applications of this ultrasonic vibration is in the industrial processes such as Electro-discharge machining (EDM), where ultrasonic vibration (UV) is inserted as a medium for enhancing the process performance. Mostly ultrasonic vibration is applied along with the EDM process to increase the efficiency of the process through debris cleansing from the sparking gap. There have been significant changes in ultrasonic assisted technology during the past years. Due to its inherent advantages, ultrasonic assistance infiltrated in different areas of EDM, such as wire cut EDM, micro EDM and die sinking EDM. This article presents an overview of ultrasonic vibration applications in electric discharge machining. This review provides information about modes of UV application, impacts on parameters of performance, optimization and process designing on difficult-to-cut materials. On the bases of available research works on ultrasonic vibration assisted EDM, current challenges and future research direction to improve the process capabilities are identified. Literature suggested improved material removal rate (MRR), increased surface roughness (SR) and tool wear ratio (TWR) due to the application of ultrasonic vibration assisted EDM. However, tool wear and surface roughness can be lessened with the addition of carbon nanofiber along with ultrasonic vibration. Moreover, the application of ultrasonic vibration to both tool and workpiece results in higher MRR compared to its application to single electrode.

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“…There have been several research studies on the EDM and micro-EDM of brass. The brass is most commonly used as electrode materials for both diesinking and wire-EDM processes [31]. Brass wire is one of the most extensively used wire electrode materials in wire-EDM.…”

Section: Introductionmentioning

confidence: 99%

Micro-EDM machinability of difficult-to-cut Ti-6Al-4V against soft brass

Moses

Jahan

2015

Int J Adv Manuf Technol

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In recent years, Ti-6Al-4V (titanium alloy grade 5) is found to be one of the most widely used materials for successful applications in aerospace, automotive, and biomedical industries because of its excellent mechanical and thermal properties, outstanding corrosion resistance, and low modulus of elasticity. However, the machining of Ti-6Al-4V by conventional machining processes has always been a challenge. This study will present a comparative experimental investigation on the micro-electro-discharge machining (micro-EDM) machinability of difficult-to-cut Ti-6Al-4V against easy-tomachine brass materials. As both materials are electrically conductive, they are machinable using micro-EDM process irrespective of their hardness. It was hypothesized that the machining performance as well as quality of micro-features would vary because of the significant differences in thermal and electrical properties of two materials. In this study, the machinability of the two materials was evaluated based on the quality of the micro-features produced by the micro-EDM. Both blind and through micro-holes and micro-slots were machined on brass and Ti-6Al-4V materials. The quality of micro-features was assessed based on the dimensional accuracy, surface finish, and profile accuracy of the features. In addition, the arrays of micro-features were machined and micro patterning was done in both materials to compare the mass production capability of micro-EDM process on those materials. It was found that the dimensional accuracy of the microfeatures on the Ti-6Al-4V was slightly inferior compared to those on brass due to significantly higher tool electrode wear during machining of titanium alloy. The machined surface of the micro-features in Ti-6Al-4V was found to suffer from resolidification of molten debris, whereas micro-features on brass was found to produce smoother surface finish. Both brass and Ti-6Al-4V materials were found to produce arrays of micro-features successfully, although the micro-features on Ti-6Al-4V had debris attached to the edge and surface. The study also investigated the causes associated with the challenges in micro-EDM of Ti-6Al-4V.

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Micro‐Electro Discharge Machining (µEDM)

Cited by 12 publications

References 72 publications

Model-Based Prediction of Plasma Resistance, and Discharge Voltage and Current Waveforms in Micro-Electrodischarge Machining

Model-Based Prediction of Plasma Resistance, and Discharge Voltage and Current Waveforms in Micro-Electrodischarge Machining

Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview

Micro-EDM machinability of difficult-to-cut Ti-6Al-4V against soft brass

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