Thermophysical-Based Modeling of Material Removal in Powder Mixed Near-Dry Electric Discharge Machining

Sundriyal, Sanjay; Yadav, Jitender; Walia, R. S.; Vipin, .; Kumar, Ramayya

doi:10.1007/s11665-020-05110-3

Cited by 13 publications

(4 citation statements)

References 39 publications

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“…Tang et al, 203 Kumar et al, 204 HuuPhan et al, 205 Sundriyal et al 206 Due to re-solidification, Powder Mixed EDM is also employed for Powder Mixed Electric discharge coating.…”

Section: Significance In the Current Eramentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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“…Tang et al, 203 Kumar et al, 204 HuuPhan et al, 205 Sundriyal et al 206 Due to re-solidification, Powder Mixed EDM is also employed for Powder Mixed Electric discharge coating.…”

Section: Significance In the Current Eramentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…Electrical discharge machining (EDM) is a widely accepted non-traditional subtractive machining technique employed to create intricate contours/forms on difficult-to-cut materials used in aerospace, automotive, marine, dies and mould-making industries [ 1 , 2 ]. Material removal in the EDM process occurs due to electro-thermal spark erosion phenomena [ 3 , 4 ]. In the EDM process, the tool and workpiece (hereafter ‘electrodes’) are connected to a high-frequency pulse generator.…”

Section: Introductionmentioning

confidence: 99%

“…As a result, a portion of the melted material present on the electrode’s surface is expelled into the dielectric medium and the remainder is re-deposited back onto the adjacent region. Therefore, each pulse removes a minuscule volume of material from the electrode’s surface which results in a crater forming [ 3 , 4 , 5 ]. Due to its tendency for reduced material removal, various techniques have been employed to improve the existing EDM process without sacrificing its inherent characteristics.…”

Section: Introductionmentioning

confidence: 99%

Analysis on the Performance of Micro and Nano Molybdenum Di-Sulphide Powder Suspended Dielectric in the Electrical Discharge Machining Process—A Comparison

Rajesh

Giridharan

2022

Nanomaterials

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The significance of suspending molybdenum di-sulphide powder particles of two distinct mean size viz. Φ40 μm and Φ90 nm into the dielectric of electrical discharge machining is analysed. Crater geometry, surface crack density, skewness, kurtosis and chemical alteration of machined surfaces are considered as outcome measures. A numerical model using finite element analysis is developed to forecast crater geometry. To validate the proposed model, experiments are conducted by varying input parameters such as discharge duration, peak current, and gap voltage. In comparison with the experimental results, the proposed model predicts diameter of crater with an error of 3.34%, 7.32% and 2.76% for discharge duration, peak current and gap voltage respectively for Φ40 μm powder; similarly, 0.19%, 3.65% and 2.78% for Φ90 nm powder. Scanning electron microscope images, 2D roughness profiles and X-ray diffraction profiles are used to assess the partial discharge phenomena, surface crack density, skewness, kurtosis and chemical alteration of the machined surface. For all parameter settings, the Φ90 nm produced surfaces with lessened micro-cracks compared to Φ40 μm. The Φ90 nm creates surfaces with negative skewness and kurtosis less than 3. The deposition of MoS2 powder particle on the machined surface is revealed through X-ray diffraction analysis.

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“…2,3 It was also illustrated that near-dry EDM with powder additives was efficient in performance characteristics such as higher material removal rate, reduced residual stress and better surface quality in the machined products. [4][5][6][7][8][9] Investigations related to field of powder mixed EDM has also been performed by researchers. Silicon carbide (SiC) powder additives were suspended in the dielectric oil for powder mixed EDM (PMEDM) to study surface topography of Ti-6Al-4V-ELI work material.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and performance enhancements characteristics of gaseous assisted powder mixed near dry electric discharge machining

Sundriyal

Vipin

Walia

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Gaseous assisted powder mixed near dry EDM (GAPMND-EDM) is one of the recent hybrid technologies, which not only enhance the machining performance, but at the same time, high quality products with better surface quality characteristics can also be achieved. In this study, the response parameters were material removal rate, surface finish, micro hardness and residual stress. It was found that the maximum material removal rate (MRR 3.379 mg/min) was achieved with combination of (dielectric) oxygen gas with graphite powder while lowest surface roughness (SR 1.11 μm) was found to be with dielectric argon gas with graphite additives. Highest micro hardness (MH) and lowest residual stress (RS) was 820.30 Vickers hardness number (VHN) and 229 MPa found with dielectric combination of zinc additives with argon gas.

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Thermophysical-Based Modeling of Material Removal in Powder Mixed Near-Dry Electric Discharge Machining

Cited by 13 publications

References 39 publications

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Analysis on the Performance of Micro and Nano Molybdenum Di-Sulphide Powder Suspended Dielectric in the Electrical Discharge Machining Process—A Comparison

Experimental investigation and performance enhancements characteristics of gaseous assisted powder mixed near dry electric discharge machining

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