On application of tool mimic approach for fabrication of functional surfaces using EDM process

Tiwari, Tanmay; Dvivedi, Akshay; Kumar, Pradeep

doi:10.1007/s40430-023-04111-2

Cited by 5 publications

(2 citation statements)

References 30 publications

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“…The material dissolution rates in electrochemical machining-based processes also depend on electrolyte type and concentration. [22][23][24] The electrolyte type combination and concentration were selected considering the merits of mixing different electrolytes on the electrochemical dissolution behaviour of Inconel 718. 21,25,26 The range of process parameters, such as applied voltage and electrolyte concentration (EC), were selected based on literature and pilot experiments.…”

Section: Methodsmentioning

confidence: 99%

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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Shaped tube electrolytic drilling (STED) is an electrochemical machining variant that employs a tubular tool electrode to produce holes with a high aspect ratio on hard-to-machine materials. The tubular electrodes with a diameter below 1 mm produce undesired residue (center-peak) at the machining surface that hampers the machining rate. Therefore, this study attempts to improve the electrolyte flow and enhance the electrochemical dissolution through tool modification. The performance enhancement of the STED process in terms of material removal rate and average diametral overcut has been explored. The issues related to the limitations in material removal in the STED process are brought forth with the technique to resolve those difficulties. The experiments were conducted with the modified tubular tool, and the length of slits on the tool was selected based on the simulation insights and pilot study. The effects of input process parameters (applied voltage, tool feed rate, electrolyte concentration, and tool slit length) on the output responses obtained from the STED process are elaborated. Holes with diameters in the range 0.89-0.97 mm and 12 mm depth were fabricated. Further optimization of the process parameters in the design space is also presented to obtain sustainable process performance.

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Section: Methodsmentioning

confidence: 99%

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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“…On the other hand, EDM proves effective in producing accurate features. 9 Nevertheless, the thermal impact of EDM negatively affects the fatigue life of machined surfaces. 10 Thermal damages, including the recast layer, subsurface alterations (e.g., heat-affected zone and converted layer), metallurgical changes, and the presence of surface defects like micro-globules, crevices, burrs, and pores, all contribute to the deterioration of components exposed to fatigue loading conditions.…”

mentioning

confidence: 99%

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Singh,

Rakurty,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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Electrical discharge micromachining (EDM) poses challenges to the fatigue-life performance of machined surfaces due to thermal damage, including recast layers, heat-affected zones, residual stress, micro-cracks, and pores. Existing literature proposes various ex-situ post-processing techniques to mitigate these effects, albeit requiring separate facilities, leading to increased time and costs. This research involves an in-situ sequential electrochemical post-processing (ECPP) technique to enhance the quality of EDMed micro-holes on titanium. The study develops an understanding of the evolution of overcutting during ECPP, conducting unique experiments that involve adjusting the initial radial interelectrode gap (utilizing in-situ wire-electrical discharge grinding) and applied voltage. Additionally, an experimentally validated transient finite element method model is developed, incorporating the passive film formation phenomenon for improved accuracy. Compared to EDM alone, the sequential EDM-ECPP approach produced micro-holes with superior surface integrity and form accuracy, completely eliminating thermal damage. Notably, surface roughness (Sa) was reduced by 80% after the ECPP. Increasing the voltage from 8 to 16 V or decreasing the gap from 60 to 20 µm rendered a larger overcut. This research's novelty lies in using a two-phase dielectric (water-air), effectively addressing dielectric and electrolyte cross-contamination issues, rendering it suitable for commercial applications.

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