Reducing Electrode Wear Using Cryogenic Cooling during Electrical Discharge Machining

Abdulkareem, Suleiman; Khan, Ahsan Ali; Konneh, Mohamed

doi:10.4028/www.scientific.net/amr.83-86.672

Cited by 12 publications

(2 citation statements)

References 9 publications

(12 reference statements)

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“…The MH has been enhanced by increasing the gap voltage (39.365 percent contribution) between tools and work surfaces. However, after level 3, the MH is slightly decreased due to the reduced cooling efficiency caused by the complete burring of dielectric fluid [32,33]. The microhardness is significantly improved due to increased heat and the cooling effect of the dielectric medium (up to Level 3).…”

Section: Microhardness (Mh) Analysismentioning

confidence: 99%

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Janardhana

Anushkannan²,

Dinakaran

et al. 2023

Eng. Res. Express

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In this research, the environment-friendly dry electrical discharge machining (EDM) process is investigated to improve the microhardness, surface finish, and white layer thickness of the machined surfaces using graphite-argon gas as a dielectric medium. The graphite powder, mixed with compressed argon gas, has been used to replace the existing dielectric medium in the EDM process. Gas pressure, discharge current, pulse width, and gap voltage were working as input parameters to reduce surface roughness and enhance the microhardness and white layer thickness. The Taguchi L16 orthogonal array is applied to the design and analysis of the experimental results. The minimum surface roughness (2.23 µm) of the HN31 steel has been attained by increasing the gas pressure up to 1.0 MPa and the minimum values of pulse width (40 µs), gap voltage (40 V), and discharge current (6 A). The maximum microhardness (501.04 HV) has been obtained at 1.2 MPa of gas pressure, 120 µs of pulse width, 60 V of gap voltage, and 18 A of discharge current. The maximum white layer thickness (16.24 µm) is achieved by the maximum values of gas pressure (1.2 MPa), pulse width (160 µs), gap voltage (70 V) and discharge current (18 A). The SEM analysis had been done to reveal the white recast layer thickness and surface roughness of the machined surfaces of the dry EDM process. The SR is increased by the recast layer, pores, and microcracks on the machined surfaces. Finally, the multi-criteria optimization technique: Weight Product Method (WPM) is applied to predict optimum process parameter settings: GP: 1.2 MPa, PW: 120 µs, GV: 50 V, and DC: 18 A to meet the best machining performances (MH=493.32 HV, WLT= 14.28 µm, and SR= 3.82 µm). The validation tests were done to confirm the predicted results obtained by both the Taguchi and WSM methods.

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Section: Microhardness (Mh) Analysismentioning

confidence: 99%

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Janardhana

Anushkannan²,

Dinakaran

et al. 2023

Eng. Res. Express

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“…The conventional method is usually used to weigh or calculate the electrode volume to evaluate EW [15,16]. Wang et al calculated the EW volume using the length difference before and after EDM and discussed the influence of electrode shape on micro hole machining [17].…”

Section: Introductionmentioning

confidence: 99%

Automatic evaluation of EDM electrode wear via integration of image segmentation and 3D registration (IS-3DR)

Ma,

Zhou,

Cui

et al. 2024

Int J Adv Manuf Technol

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Electrode wear (EW) during the electrical discharge machining (EDM) process determines surface topography accuracy. In this paper, an automatic evaluation method is proposed by integrating image segmentation and three-dimensional (3D) registration (IS-3DR) to evaluate the EW more accurately. First, the original two-dimensional (2D) image and the 3D point cloud were derived from a laser microscope image, and the 2D worn area was determined by automatic recognition and segmentation. Then, 3D registration between the 3D point cloud and the 2D worn area was utilized to qualitatively define the 3D EW area. Finally, the 3D EW volume was obtained quantitatively through microelement calculation based on the 3D EW area and the shape fitting of the original electrode. The results showed that the intersection over union (IOU) of image segmentation was higher than 97.5%, compared with the manually labeled image segmentation method. The reliability of the proposed IS-3DR evaluation method was confirmed. Additionally, EDM experiments are carried out to verify the proposed IS-3DR evaluation method. The impact of various discharge parameters on EW was illustrated in detail.

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Experimental studies on electro-discharge machining of Inconel 825 super alloy using cryogenically treated tool/workpiece

2019

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Reducing Electrode Wear Using Cryogenic Cooling during Electrical Discharge Machining

Cited by 12 publications

References 9 publications

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Automatic evaluation of EDM electrode wear via integration of image segmentation and 3D registration (IS-3DR)

Experimental studies on electro-discharge machining of Inconel 825 super alloy using cryogenically treated tool/workpiece

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