Performance analysis of tool electrode prepared through laser sintering process during electrical discharge machining of titanium

Sahu, Anshuman Kumar; Mahapatra, Siba Sankar

doi:10.1007/s00170-019-04675-1

Cited by 32 publications

(11 citation statements)

References 39 publications

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“…The different tool types and grades that are used in conventional machining operations are listed in Table S1 [ 117,[119][120][121][124][125][126][127][128][129][130][131][132]. Although different tool wear mechanisms such as plastic deformation, adhesion and abrasion were mentioned in the preceding paragraphs, crater wear has been reported as the main mechanisms affecting the life span of cutting tools especially at cutting speed of 61-122 m/min [33,88].…”

Section: Exploration Of Cutting Toolsmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

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Section: Exploration Of Cutting Toolsmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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“…They optimized the EDM process parameters but found that the excessive wear of the electrode and the high level of porosity limit the application. Sahu and Mahapatra [ 4 , 5 ] tested the behavior of AlSi10Mg electrodes made by PBF and tested on the EDM of titanium. They concluded that, in terms of surface characteristics of the part (roughness, surface crack density, white layer thickness, microhardness), the results were acceptable, but in terms of the material removal rate (MRR) and tool wear rate (TWR), the results were worse than using conventional electrodes, such as graphite.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of the Performance of Atomic Diffusion Additive Manufacturing Electrodes in Electrical Discharge Machining

2022

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Atomic Diffusion Additive Manufacturing (ADAM) is an innovative Additive Manufacturing process that allows the manufacture of complex parts in metallic material, such as copper among others, which provides new opportunities in Rapid Tooling. This work presents the development of a copper electrode manufactured with ADAM technology for Electrical Discharge Machining (EDM) and its performance compared to a conventional electrolytic copper. Density, electrical conductivity and energy-dispersive X-ray spectroscopy were performed for an initial analysis of both ADAM and electrolytic electrodes. Previously designed EDM experiments and optimizations using genetic algorithms were carried out to establish a comparative framework for both electrodes. Subsequently, the final EDM tests were carried out to evaluate the electrode wear rate, the roughness of the workpiece and the rate of material removal for both electrodes. The EDM results show that ADAM technology enables the manufacturing of functional EDM electrodes with similar material removal rates and rough workpiece finishes to conventional electrodes, but with greater electrode wear, mainly due to internal porosity, voids and other defects observed with field emission scanning electron microscopy.

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“…Titanium and its alloys have been widely used in aerospace and biomedical applications due to attractive properties, such as high specific strength, excellent corrosion resistance, and cryogenic properties [1][2][3]. However, as a difficult-to-machine material, titanium and its alloys are difficult to be machined by traditional machining methods, especially when involving a micro-scale feature.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Liu

Chen³

et al. 2021

Materials

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Micro electrical discharge machining (micro EDM) is able to remove conductive material by non-contact instantaneous high temperature, which is more suitable for machining titanium and its alloys compared with traditional machining methods. To further improve the machining efficiency and machined surface quality of micro EDM, the nano particle surfactant mixed micro EDM method is put forward in this paper. Experiments were conducted to explore the effect of nano particle surfactant on the micro EDM performance of titanium alloy. The results show that the material removal rate of micro EDM in dielectric mixed with TiO2 is the highest when open-circuit voltage is 100 V, followed by Al2O3 and ZrO2. Lower tool wear rate can be produced by using dielectric mixed with nano particle surfactant. The taper ratio of micro EDM in dielectric mixed with nano particle surfactant is higher than that in deionized water. The surface roughness Ra of micro EDM in dielectric mixed with TiO2 can be 50% lower than that in deionized water. It is helpful to improve the machining performance by adding surface surfactant in the dielectric of micro EDM.

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Performance analysis of tool electrode prepared through laser sintering process during electrical discharge machining of titanium

Cited by 32 publications

References 39 publications

An overview of conventional and non-conventional techniques for machining of titanium alloys

An overview of conventional and non-conventional techniques for machining of titanium alloys

Evaluation of the Performance of Atomic Diffusion Additive Manufacturing Electrodes in Electrical Discharge Machining

An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

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