Micro-machining through electrochemical discharge processes: a review

Kumar, Nitesh; Mandal, Niladri; Das, Alok Kumar

doi:10.1080/10426914.2020.1711922

Cited by 87 publications

(40 citation statements)

References 178 publications

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“…The process factors are divided into the electrical and non-electrical factors on which the machined surface characteristics depend. Current, applied voltage, pulse-on duration, and pulse-off duration are the most influential electrical variables, while the non-electrical input vari-ables include the physical properties of the tools, working liquid, particle size, and the amount of powder added [11,23,[181][182][183][184][185][186][187][188]. Considering that a PM-EDM system is complex in nature, optimization of the process factors is required to obtain the optimum responses.…”

Section: Pm-edm Process Variables Affecting the Treated Surface Propertiesmentioning

confidence: 99%

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

et al. 2021

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Together, 316L steel, magnesium-alloy, Ni-Ti, titanium-alloy, and cobalt-alloy are commonly employed biomaterials for biomedical applications due to their excellent mechanical characteristics and resistance to corrosion, even though at times they can be incompatible with the body. This is attributed to their poor biofunction, whereby they tend to release contaminants from their attenuated surfaces. Coating of the surface is therefore required to mitigate the release of contaminants. The coating of biomaterials can be achieved through either physical or chemical deposition techniques. However, a newly developed manufacturing process, known as powder mixed-electro discharge machining (PM-EDM), is enabling these biomaterials to be concurrently machined and coated. Thermoelectrical processes allow the migration and removal of the materials from the machined surface caused by melting and chemical reactions during the machining. Hydroxyapatite powder (HAp), yielding Ca, P, and O, is widely used to form biocompatible coatings. The HAp added-EDM process has been reported to significantly improve the coating properties, corrosion, and wear resistance, and biofunctions of biomaterials. This article extensively explores the current development of bio-coatings and the wear and corrosion characteristics of biomaterials through the HAp mixed-EDM process, including the importance of these for biomaterial performance. This review presents a comparative analysis of machined surface properties using the existing deposition methods and the EDM technique employing HAp. The dominance of the process factors over the performance is discussed thoroughly. This study also discusses challenges and areas for future research.

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Section: Pm-edm Process Variables Affecting the Treated Surface Propertiesmentioning

confidence: 99%

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

et al. 2021

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“…The micro-electro chemical discharge machining process is emerging as a promising micromachining process for developing 2D and 3D micro features in electrically conductive and non-conductive materials. It is frequently used in machining brittle and difficult-to-cut materials, such as glass, quartz, ceramic [2] and metal matrix composites [3].…”

Section: Introductionmentioning

confidence: 99%

“…Further, a mathematical model was developed by another investigator to understand or guide the machining operation [14]. Several approaches were stated earlier in this work to enhance the machining speed, dimensional accuracy, surface quality and removal rate of material [2]. However, despite numerous advantages, these hybrid processes require special attachments/approaches, making the machining operation expensive and complex [10].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Maraging Steel Surface Integrity in Hybrid and Conventional Micro-ECDM Processes

2022

Self Cite

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Maraging steel is one of the exotic materials showing the potential for application in the field of the aerospace industry. However, machining these materials with high surface quality and material removal rate is problematic. The micro-electro chemical discharge (MECDM) process is capable of resolving this problem to some extent, however, due to the spark action, it fails to attain a high surface finish. In the current investigation, micro-hole drilling is performed on maraging steel with powder-mixed alumina (1% wt. of Al2O3) using the micro-electro chemical discharge machining (PMECDM) process. The effect of different input process factors, for example, voltage (V), duty cycle (D), the electrolyte concentration (C), are considered for investigating the machining performance, i.e., rate of material removal (MRR) and roughness of surface (SR) of the machined substrate. Further, a comparative analysis is established between micro-ECDM (MECDM) and mixed powder ECDM (PMECDM). The Box–Behnken design is used to conduct all the experiments and analysis of variance (ANOVA) is used to optimize the results. The outcomes reveal that MRR in PMECDM is enhanced by 34%, and the average surface roughness is reduced by 21% over the MECDM process. The maximum MRR was observed to be 2.44 mg/min and the hole machined by the PMECDM results in a cleaner hole wall surface than the MECDM process due to the grinding action by the powder particles. The residual stress measurement indicates that the PMECDM (−128.3 ± 3.85 MPa) has the lowest equivalent stress as compared to the parent material (−341.04 ± 10.24 MPa) and MECDM (−200.7 ± 6.02 MPa) surfaces. The applied voltage is the most significant parameter, followed by the duty factor and electrolyte concentration for enhancing the MRR and surface finish. The addition of powder improves the surface integrity of the machined surface as compared to the surfaces produced by the MECDM processes.

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“…For example, in a review paper, Kumar et al made a comparison between µ-EDM, µ-ECM, and µ-ECDM for industrial and research use [7]. They point out that at least micro-ECM and micro-ECDM are superior to micro-EDM on both the higher MRR (removal rate) and the more refined surface finish and more minor thermal-induced defects (such as HAZ, recast layers, and microcracks).…”

Section: Introductionmentioning

confidence: 99%

Deionized Water Electrochemical Machining Hybridized with Alumina Powder Polishing for Microcavity of M-333 Mold Steel

Hsue¹,

Huang²

2022

Processes

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An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-water) and an ECM polishing hybrid with alumina powder of 1.0 μm grains on a single micro-EDM machine are proposed. The process adopts tungsten carbide as tool electrode and M-333 tool steel as the mold material. It reveals that employing the 30 μm/min feed rate with 50 mA and 0.2 ms of pulse-width is suitable for DI-water electrochemical machining. The DI-water ECM process can achieve an excellent surface roughness at Ra 0.169 µm on a semispherical round cavity. Combining the ECM with hybrid polishing with the alumina powder can achieve a better profile for a much deeper cavity than pure electrolytic discharge machining. The hybrid ECM polishing can efficiently finish a micro square insert of 0.6 mm length at 64 μm depth. Such ECM milling can achieve an S-shaped microchannel of radius 1.0 mm and a slot of 1.0 × 0.5 mm2 with 110 μm depth, demonstrating its feasibility and the surface integrity with accurate profile and roughness of Ra 0.227 μm. This study provides a cost-effective scheme for micro mold fabrication with a conventional micro-EDM machine tool and an intuitive and convenient optional process. However, some micro-electrical discharges occurred due to the breakdown of insulation, which creates micro craters on the surface of the parts.

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Micro-machining through electrochemical discharge processes: a review

Cited by 87 publications

References 178 publications

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

Comparison of Maraging Steel Surface Integrity in Hybrid and Conventional Micro-ECDM Processes

Deionized Water Electrochemical Machining Hybridized with Alumina Powder Polishing for Microcavity of M-333 Mold Steel

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