Optimization of Dry EDM Milling Process

Skrabalak, Grzegorz; Kozak, J.; Zybura, Maria

doi:10.1016/j.procir.2013.03.027

Cited by 21 publications

(7 citation statements)

References 7 publications

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“…The results obtained by these methods proved that FEM and FDM, are powerful tools to be used for estimating the temperature distribution considering variable thermo-physical properties. Skrabalak et al (2013) have studied the dry EDM milling process and showed that machining efficiency is not satisfactory with argon and nitrogen as compared to other gases, namely, oxygen, compressed air, etc. This study also concludes that tool wear is practically negligible in the air as a dielectric medium.…”

Section: Literature Reviewmentioning

confidence: 99%

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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Purpose Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM). Design/methodology/approach This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining. Findings It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM. Originality/value The range of predicted results and the experimental results are in close agreement, authenticating the model.

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Section: Literature Reviewmentioning

confidence: 99%

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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show abstract

“…between the tool electrode and workpiece to be machined. 23–25 On the other hand, near-dry EDM uses liquid–air/gas mixture or mist (at very high pressure) as the dielectric medium. Besides its environmental friendliness, high productivity, and surface quality makes near-dry EDM process a promising substitute of conventional EDM.…”

Section: Nonconventional Machining and Sustainable Productionmentioning

confidence: 99%

Developments in nonconventional machining for sustainable production: A state-of-the-art review

Gupta

2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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Nonconventional or advanced machining processes such as electric discharge machining, electrochemical machining, abrasive water jet machining, and laser beam machining have been widely used as a viable alternate to the conventional processes to manufacture high-quality engineered parts having certain typical features. In spite of their special features, wider acceptance, and use, they suffer from certain inherent limitations with regard to sustainability such as high consumption of energy and resources; generation of toxic liquid, gases, and solid wastes; risk for health and safety; air pollution; generation of waste and its disposal problems; and workpiece contamination and thermal damage to the parts being produced. It is found that these factors all adversely affect the environment to a certain extent. Innovative sustainable techniques such as dry, near-dry, and green electric discharge machining; green and hybrid electrochemical machining; ice-jet machining; and eco- and underwater laser beam machining, etc. have been developed to address sustainability challenges and greatly benefited with improvements in quality, productivity, and sustainability. This review article first introduces four major nonconventional machining processes, discusses their inherent sustainability issues and challenges, and presents state-of-the-art review of the work conducted using sustainable innovative techniques and strategies with an aim to encourage academics, researchers, and engineers for research and developments in order to establish the field further. The literature review offered in this article is based on over 80 articles published from 1975 to 2017. Finally, the article ends up with concluding remarks and recommending possible avenues to stimulate future research.

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“…This removes (erodes) very tiny pieces of metal from the work material at a controlled rate. The metal removal mechanism of this process is excellently detailed out in (Ho & Newman, 2003;Liu et al, 2008;Rajurkar et al, 2013;Skrabalak et al, 2013). Mehfuz and Ali (2009) studied the effects of three micro electro discharge milling process parameters, i.e.…”

Section: Example 1: Micro Electro Discharge Milling Processmentioning

confidence: 99%

Parameter selection in non-traditional machining processes using a data mining approach

Dey¹,

Chakraborty²

2015

10.5267/j.dsl

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With ever-increasing demands for high surface finish and complex shape geometries on various difficult-to-machine materials, conventional metal removal methods are now being replaced by nontraditional machining (NTM) processes. These NTM processes use energy in its direct form to remove material from the workpiece surface. They are also cost effective for a wide range of microand nano-level applications. For effective utilization of different NTM processes, it is quite important to study their characteristics and material removal mechanisms in order to identify the most significant control parameters affecting the process responses. In this paper, a data mining approach using classification and regression tree algorithm is employed to identify the most important input parameters of three NTM processes, i.e. micro electro discharge milling process, wire electrical discharge machining process and laser beam machining process. The derived observations are also validated using the analysis of variance results.Growing Science Ltd. All rights reserved. 5

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Optimization of Dry EDM Milling Process

Cited by 21 publications

References 7 publications

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Developments in nonconventional machining for sustainable production: A state-of-the-art review

Parameter selection in non-traditional machining processes using a data mining approach

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