Research on Shape Changes in Cylinder Electrodes Incident to Micro-EDM

Li, Xiaopeng; Wang, Yuangang; Liu, Yu; Zhao, Fu

doi:10.1155/2019/8087462

Cited by 6 publications

(4 citation statements)

References 25 publications

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“…Only for negatively polarized tool electrodes, as in the present case, LI ET AL. revealed similar concave contours of the electrode tip and explained this fact with the skin effect and a decreased discharge probability in the center [87]. The authors did not attribute this concavity to the ejection of debris, but from their SEM images, it can be supposed that the center concavity deepened as a result of the increasing rotational speed [87] (p. 9).…”

Section: Resultsmentioning

confidence: 93%

“…revealed similar concave contours of the electrode tip and explained this fact with the skin effect and a decreased discharge probability in the center [87]. The authors did not attribute this concavity to the ejection of debris, but from their SEM images, it can be supposed that the center concavity deepened as a result of the increasing rotational speed [87] (p. 9). It can therefore be further concluded that the concave tip contour was also a consequence of accumulated debris in the frontal working gap due to the absence of pressure flushing, supporting the formation of a stationary vortex.…”

Section: Resultsmentioning

confidence: 93%

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Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

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The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.

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Section: Resultsmentioning

confidence: 93%

Section: Resultsmentioning

confidence: 93%

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

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“…To identify the influence of the tool during groove-grinding with a micro-tool, the edge radius of the tool was analyzed. In EDM, the current was concentrated in a sharp part such as an edge during machining [27], and resulted in the rounding of the edge. If the discharge energy is reduced using a condenser with a small capacitance, sharper edges can be obtained with a smaller energy.…”

Section: Machining Characteristics Of Zirconiamentioning

confidence: 99%

Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

Lee

Kim

2021

Applied Sciences

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In this study, micro-grinding was performed to investigate the machining characteristics of alumina and zirconia. The machining of ceramics remains highly challenging owing to their properties, such as high brittleness and wear resistance, which leads to a shorter tool life and high machining costs. Polycrystalline diamond (PCD) was selected as the tool material, as it is suitable for machining hard and brittle materials, and micro-electrical discharge machining (EDM) was used to fabricate PCD micro-tools. When using a resistor-capacitor generator circuit in micro-EDM, the discharging energy is related to the working capacitance, and by controlling the working capacitance, the different edge radii and the surface roughness of the tool can be easily achieved. The feed rate, depth of cut, and rotation speed were set as experimental parameters to investigate the grinding characteristics of the ceramics. During the experiment, the grinding force and roughness of the bottom surface were monitored, and the roughness of the machined surfaces was measured using a three-dimensional surface profiler. A working capacitance of 1000 pF was used to fabricate a tool with an edge radius of 3.5 µm. The lower radius of the tool edge resulted in a decrease of the cutting force by 50% at most and a surface roughness of 19 nm Ra.

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“…Electric Discharge Machine (EDM) is a well-known and advanced process used to machine high precision dies, molds, and various other parts with complex features and high aspect ratio [1].…”

Section: Introductionmentioning

confidence: 99%

A Technique of Tool Manufacturing by changing the Polarity of EDM

2021

IJETER

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Sandeep Lakraet al.,InternationalJournal of Emerging Trends in Engineering Research, 9(5), May 2021, 587–591587A Technique of Tool Manufacturing by changing thePolarity of EDMSandeep Lakra1, Rahul Charles Francis21,2Department of Mechanical Engineering, Vaugh Institute of Agricultural Engineering and Technology, Sam Higginbottom University of Agriculture, Technology and Sciences, Prayagraj, Uttar Pradesh, India-2110071Tony007sandeep@gmail.com2Rahul.francis@shiats.edu.inABSTRACTIn today’s modern era, cutting processes involves many vast technologies. EDM process is one of the advancedmetalcutting processes. Since most of the tools are made from conventional processes in the lathe machine. This paper proposes a technique to manufacture some specific tools by changing the polarity in EDM. Changing the polarity means changing the path of the electronfrom tool to workpiece and workpiece to tool. This results more accurately and easily for manufacturing of complex-shaped tools

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Research on Shape Changes in Cylinder Electrodes Incident to Micro-EDM

Cited by 6 publications

References 25 publications

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

A Technique of Tool Manufacturing by changing the Polarity of EDM

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