The delamination effect of drilling and electro-discharge machining on the tensile strength of woven composites as studied by X-ray computed tomography

Korlos, Apostolos; Tzetzis, Dimitrios; Mansour, Gabriel; Sagris, Dimitrios; David, Constantine

doi:10.1504/ijmmm.2016.077712

Cited by 6 publications

(6 citation statements)

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“…The material removal rate is an important consideration; altering the machining gap can increase the material removal rate, as well as improve surface finish [24]. The EDM process has been widely used for manufacturing molds and dies, as well as in the aerospace and automotive industries [25][26][27][28][29][30]. However, problems with deep hole machining or deep hole drilling often lead to undesirable surface quality and geometry problems.…”

Section: Introductionmentioning

confidence: 99%

Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode

Jamkamon

Janmanee

2021

Applied Sciences

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The performance of electrical discharge machining for drilling holes decreases with machining depth because the conventional flushing and electrode cannot completely eliminate debris particles from the machining area. In this study, a modified electrode for self-flushing in the electrical discharge machining process with a step cylindrical shape was designed to improve machining performance for deep hole drilling. The experimental results of the step cylindrical electrode showed that the material removal rate increased by approximately 215.7%, 203.8%, and 130.4%, and the electrode wear ratio decreased by approximately 47.2%, 63.1%, and 37.3%, when compared with a conventional electrode for the diameters of 6, 9, and 12 mm, respectively. In addition, the gap clearance and concavity of the side wall of the drilled hole was reduced with the step cylindrical electrode. The limited high flank of the electrode led to an increase in the escape area of the debris that was partially removed from the machining area, and the limited secondary spark on the side wall of the electrode resulted in a reduction in machining time.

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Section: Introductionmentioning

confidence: 99%

Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode

Jamkamon

Janmanee

2021

Applied Sciences

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“…The results showed that increasing the current (from 2A to 12A) reduced the cutting time (by 60.95%) while keeping all other parameters constant. Likewise, in similar studies [34][35][36][37][38][39][40][41][42][43][44][45][46][47][48] related to the WIRE-EDM of PCMs, it was observed that the quality and accuracy of holes in a low-conductive material can be regulated by applying a conductive layer above the non-conductive PCM. Also, the development of theoretical models of the WIRE-EDM of PCMs provides a guide to obtain the accuracy required in the process [37].…”

Section: Introductionmentioning

confidence: 83%

Analysis of Wire-Cut Electro Discharge Machining of Polymer Composite Materials

et al. 2021

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This study presents the analysis of wire-cut electro-discharge machining (WIRE-EDM) of polymer composite material (PCM). The conductivity of the workpiece is improved by using 1 mm thick titanium plates (layers) sandwiched on the PCM. Input process parameters selected are variable voltage (50–100 V), pulse duration (5–15 μs), and pause time (10–50 μs), while the cut-width (kerf) is recognized as an output parameter. Experimentation was carried out by following the central composition design (CCD) design matrix. Analysis of variance was applied to investigate the effect of process parameters on the cut-width of the PCM parts and develop the theoretical model. The results demonstrated that voltage and pulse duration significantly affect the cut-width accuracy of PCM. Furthermore, the theoretical model of machining is developed and illustrates the efficacy within the acceptable range. Finally, it is concluded that the model is an excellent way to successfully estimate the correction factors to machine complex-shaped PCM parts.

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“…Microtool electrodes with a scale of several microns can be fabricated; therefore, the size of machined structures can also reach the level of several microns [ 1 ]. This process is particularly suitable for machining both hard-to-cut [ 2 , 3 , 4 , 5 , 6 ] and easily deformed conductive materials [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling

Zhang

et al. 2021

Micromachines

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In micro-electrical discharge machining (micro-EDM) milling, the cross-section of the microgroove machine is frequently not an ideal rectangle. For instance, there are arc shapes on the bottom and corners, and the sidewall is not steep. The theoretical explanation for this phenomenon is still lacking. In addition to the tip discharge effect, the essential reason is that there is an accumulative difference in time and space during the shape change process of a tool electrode and the microstructure formation on a workpiece. The process parameters are critical influencing factors that determine this accumulative difference. Therefore, the accumulative difference mechanism in time and space is investigated in this paper, and then a theoretical model is developed to simulate the micro-EDM milling process with a straight-line single path. The simulation results for a cylindrical electrode at the two rotational speeds of 0 (nonrotating) and 300 rpm are compared, while the results for a cylindrical electrode and a square electrode at a rotation speed of 0 are also compared to verify that different process parameters generate accumulative differences in the time and space of material removal. Finally, micro-EDM milling experiments are carried out to verify the simulation model. The maximum mean relative deviation between the microgroove profiles of simulation results and those of experiments is 11.09%, and the profile shapes of simulations and experiments have a good consistency. A comparative experiment between a cylindrical electrode and a hollow electrode is also performed, which further verifies the mechanism revealed in the study. Furthermore, the cross-section profile of a microgroove can be effectively controlled by adjusting the process parameters when utilising these accumulative differences through fabricating a microgroove with a V-shaped cross-section by a square electrode and a microgroove with a semi-circular cross-section by a cylindrical electrode. This research provides theoretical guidance for solving the problems of the machining accuracy of detail features in micro-EDM milling, for instance, to machine a microgroove with an ideal rectangular cross-section.

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The delamination effect of drilling and electro-discharge machining on the tensile strength of woven composites as studied by X-ray computed tomography

Cited by 6 publications

References 0 publications

Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode

Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode

Analysis of Wire-Cut Electro Discharge Machining of Polymer Composite Materials

An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling

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