Modelling of material removal rate in the magnetic field and air-assisted electrical discharge machining

Beravala, Hardik; Pandey, Pulak M.

doi:10.1177/0954406219892297

Cited by 7 publications

(4 citation statements)

References 35 publications

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“…This provided adequate time for the removal of debris from the machining zone. Hence, fewer recast layers were formed at a low duty cycle and as a result surface roughness decreased [33]. Further, from Figure 9(c) it can be seen that SR was found more in AAEDD in comparison to REDD.…”

Section: Influence Of Process Parameters On Srmentioning

confidence: 88%

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Electric discharge drilling with gas-assisted multi-hole slotted tool

et al. 2020

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This paper proposes the use of a novel electrode containing modified design explicitly intended to promote gas-assisted tool rotation-induced debris removal. The proposed tool was observed to be efficient in dispensing the accumulation of eroded materials from the discharge gaps. In this work, the influence of process parameters like discharge current, tool speed, gas pressure, pulse duration, and duty cycle has been investigated on output responses: material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). A comparative study of the output responses was made with a solid rotary tool and the gas-aided multi-hole slotted tool. The outcome reveals that the application of the multi-hole slotted tool increased the MRR in Air assisted electric discharge machining (AAEDD) by 40-80%. Besides this, the EWR decreased in AAEDD by 17-25% compared to rotary electric discharge machining (REDD). Moreover, the SR of the AAEDD process was comparatively higher (9-15%) than that of the REDD process. It has been found less surface crack, micropores and recast layers on specimens machined by the AAEDD process in comparison to the REDD process. This work proposed a novel method for improving the machining performance by improving the flushing efficiency of the machining gap on the way to improve the material removal mechanism.

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Section: Influence Of Process Parameters On Srmentioning

confidence: 88%

“…The reaction is exothermic, which transfers heat to the discharge crater as seen by the chemical reaction (2Fe + 1.5O 2 → Fe 2 O 3 + heat) [33]. However, the multi-hole tool with slot facilitated the effective spreading of dielectric, as this speed up the removal of eroded maters from the spark zone.…”

Section: Effect Of Process Factors On Mrrmentioning

confidence: 99%

Electric discharge drilling with gas-assisted multi-hole slotted tool

et al. 2020

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“…At moderate energy levels, the model exhibited an average error of 10% in predicting crater diameters and a 9% error in predicting depths for single spark discharges. Beravala and Pandey [98] formulated a mathematical model to predict the MRR in the context of EDM, considering the combined influences of air and magnetic fields. The developed mathematical model primarily accounted for three physical phenomena: the decrease in energy density resulting from plasma expansion, the increase in the MRR due to assistance from a liquid-gas medium, and the reduction in the electron mean free path due to the presence of a magnetic field.…”

Section: Materials Removal Ratementioning

confidence: 99%

Progress in Simulation Modeling Based on the Finite Element Method for Electrical Discharge Machining

Li,

Sun,

Xing

et al. 2023

Metals

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Electrical Discharge Machining (EDM) is a machining method commonly used to produce complex shapes and deep holes by eroding hard metals with an electric arc. There is a growing demand for process simulation using finite element models in order to improve the quality and efficiency of EDM, to reduce costs, to improve resource efficiency, and to facilitate its application in critical areas such as aerospace and mechanical engineering. Finite element models have greatly improved the prediction accuracy of EDM processes, simulated complex hybrid machining processes, and provided important guidance for the optimization of EDM processes. This paper systematically reviews the research progress of finite element modeling for EDM. Finite element method modeling is evaluated mainly in terms of four indicators: material removal rate, surface roughness, tool wear ratio, and recast layer thickness. Firstly, the importance and application of EDM are described, and the EDM finite element method modeling and its advantages are summarized. Then, the single-spark simulation model and the multi-spark simulation model of EDM are compared and discussed. Among the mainstream finite element models, the prediction error of the material removal rate for single-spark simulation ranges from 8.2% to 14.75%, while the prediction error of the recast layer thickness for multi-spark simulation can be as low as 1.98%. Finally, the applications of finite element modeling in EDM hybrid machining processes’ performance prediction and new material machining are summarized, and future research directions and trends in EDM finite element modeling are predicted.

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“…In theoretical and simulation studies, Heinz [7] analyzed the influence mechanism of magnetic field on plasma binding and plasma stability improvement when magnetic field acts on non-magnetic materials processed by fine EDM, and proved the mechanism of Lorentz force on material erosion. Beravala [8] used the air and magnetic field composite method to assist EDM to improve the material removal efficiency, and analyzed the effects of plasma expansion, electron free path reduction, and liquid-air mixing media in detail, and the results proved that the prediction model has high accuracy. Manesh [9] established a two-dimensional magnetic field-assisted EDM single-pulse material ablution model, and found that the Lorentz force under the magnetic field is conducive to the erosion of the material through the analysis of simulation and experimental results.…”

Section: Introductionmentioning

confidence: 99%

The influence mechanism of Halbach array magnetic field control on discharge channels in EDM

Qiu,

Tang,

et al. 2024

Phys. Scr.

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The use of magnetic field to actively control Electrical Discharge Machining(EDM) can effectively improve the problems of low material removal rate and poor surface quality, but due to the limitation of materials, the magnetic induction intensity of permanent magnets after magnetization is not high, and the magnetic induction lines of permanent magnets are too concentrated and difficult to control. In order to overcome the above shortcomings, this study applied the Halbach array magnetic field to the field of EDM for the first time, established a model of the trajectory of the charged particle beam in the discharge channel, analyzed the influence of the Halbach array magnetic field on the discharge channel, and clarified the improvement mechanism of the Halbacch array magnetic field in EDM. In addition, several sets of experiments were carried out by controlling the distance between the workpiece and the working surface of the Halbach array permanent magnets. The experimental results show that when the distance between the workpiece and the working surface of the Halbach array permanent magnet is less than 10mm, the material erosion rate of the workpiece increases significantly, and the electrode loss rate and surface roughness decrease significantly. When the workpiece is 0mm away from the working surface, the material removal rate is increased by 18.18%, material removal rate increased from 0.4513mm3/min to 0.5333mm3/min, the tool wear ratio is reduced by 46.87%, tool wear ratio decreased from 0.2587 mm3/min to 0.13745 mm3/min, and the surface roughness is reduced by 39.56%, surface roughness decreased from 4.186μm to 2.53μm.

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Modelling of material removal rate in the magnetic field and air-assisted electrical discharge machining

Cited by 7 publications

References 35 publications

Electric discharge drilling with gas-assisted multi-hole slotted tool

Electric discharge drilling with gas-assisted multi-hole slotted tool

Progress in Simulation Modeling Based on the Finite Element Method for Electrical Discharge Machining

The influence mechanism of Halbach array magnetic field control on discharge channels in EDM

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