Micro-hardness evaluation for surface alloying of H11 die steel with Cu–Cr–Ni powder metallurgy tool in electrical discharge machining

Gill, Amoljit Singh; Kumar, Sumit

doi:10.1177/0954405416646027

Cited by 12 publications

(5 citation statements)

References 23 publications

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“…The electrode was said to have improved the microhardness of the workpiece's surface by 93.7%. In a separate study, Gill and Kumar [151] reported an increase of 96.3% in the microhardness of a machined surface using a Cu-Cr-Ni P/M tool from that of the base material. Murray et al [152] successfully altered the surface of a 304 stainless steel workpiece by depositing a composite coating through the EDC method and successive coating with a TiC P/M sintered tool and a Si tool.…”

Section: Powder Metallurgy Edm Electrodementioning

confidence: 96%

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Garba,

Abdul-Rani,

Yunus

et al. 2023

Machines

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In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted.

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Section: Powder Metallurgy Edm Electrodementioning

confidence: 96%

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Garba,

Abdul-Rani,

Yunus

et al. 2023

Machines

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“…Open circuit voltage increases the TWR and surface roughness. Gill AS et al [77,78] made a surface alloying on die steel with Cu-Ni-Cr composite electrode and explained spark energy is directly proportional to discharge voltage. Liew PJ et al [79] described the relationship between discharge voltage and spark gap.…”

Section: Discharge Voltage and Gap Voltagementioning

confidence: 99%

Electric discharge coating process: a critical review with potential application

Kumaran

Muralidharan²

2023

Eng. Res. Express

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Electric discharge coating (EDC) process is a competitive surface coating technology that alters the desired surface characteristics. EDC process deposits the material on the substrates from the sacrificial electrode by spark erosion process with the potential advantage of depositing any materials. This paper extensively reviews the work carried out in the EDC process and suggests areas of improvement for easy adaptability in industrial applications. Here, the variants of the EDC process, the route map for process parameter selection, the advantage over conventional methods, and coating characterization are discussed. The review sequentially presents the fundamental process, detailed analysis of tool and workpiece materials used, process parameters, and applications. EDC process has continued to be a key solution for many industrial needs, with the critical advantage of enhancing the substrate's serviceability and protecting against corrosion, thermal stress, and other adverse environmental conditions. The scope of the work is discussed in detail, with potential industrial and biomedical applications suggesting avenues for researchers and industrialists.

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“…where T p is the initial temperature (K), ρ av is the average density from initial ionization to breakdown (kg/m 3 ), and τ g is the time from initial ionization to breakdown(s). The initial pressure of plasma P nuc can be obtained from Equation (5). Because the plasma expansion can be neglected in the breakdown process, r c can be considered as the initial radius of the plasma, and its value can be obtained by Equation (9).…”

Section: Formation and Expansion Of Discharge Plasmas Of Micro-edmmentioning

confidence: 99%

“…In recent years, more and more attention has been paid to precision machining technology and methods [1,2]. As one of the most popular microfabrication methods, micro-electrical discharge machining (micro-EDM) has been widely applied to fabricate various difficult-to-cut materials [3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Study on the Time-Varying Characteristics of Discharge Plasma in Micro-Electrical Discharge Machining

Liu

Zhang

et al. 2019

Coatings

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Micro electrical discharge machining (micro-EDM) has been widely applied in the field of precision machining, but the machining mechanism is still unclear. In this paper, the relationship between the characteristics of discharge plasma and discharge duration is clarified by analyzing the formation and expansion process of the discharge plasma channel under micro-scale discharge conditions. Based on the experimental results, the effects of discharge duration on the discharge current, discharge voltage and discharge crater size are discussed. The results show that the expansion acceleration, internal pressure, temperature, and electron density of the discharge plasma decrease as the discharge duration increase, while the radius and expansion velocity of the discharge plasma increase, and finally the discharge plasma reaches the state of shape–position equilibrium. The resistance of discharge plasma is estimated to fluctuate in the range of 38–45 Ω by the ratio of discharge maintenance voltage to discharge current. The energy utilization rate of micro-EDM is very high when discharge duration is less than 4 μs, and then decreases gradually as the discharge duration increased. There is a positive linear relationship between discharge crater volume and discharge duration. The discharge duration has no significant effect on the discharge crater depth. This study provides a theoretical basis for further study of discharge plasma characteristics in micro-EDM.

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Micro-hardness evaluation for surface alloying of H11 die steel with Cu–Cr–Ni powder metallurgy tool in electrical discharge machining

Cited by 12 publications

References 23 publications

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

A Review of Electrode Manufacturing Methods for Electrical Discharge Machining: Current Status and Future Perspectives for Surface Alloying

Electric discharge coating process: a critical review with potential application

Study on the Time-Varying Characteristics of Discharge Plasma in Micro-Electrical Discharge Machining

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