Ultrasonic vibration–assisted electric discharge machining: A research review

Khatri, Bharat C.; Rathod, Pravin P.; Valaki, Janak B.

doi:10.1177/0954405415573061

Cited by 60 publications

(27 citation statements)

References 56 publications

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“…The effective implementation of the technique either ultrasonic [150] vibration-assisted or laser beam-assisted EDM is widely used. In case of ultrasonic-assisted EDM (UAEDM), combining of EDM with ultrasonic vibrations is found to be one of the most effective shared hybrid machining processes with increased metal removal rate during machining of electrically conductive very hard materials [157]. Hybrid machining process which combines laser and micro-EDM processes for drilling microholes in complex engineering materials such as nickel-titanium (Ni-Ti)-based shape memory alloy (SMA) is an example of recent use of hybrid machining process technique [158].…”

Section: Hybrid Machining Process Using Edmmentioning

confidence: 99%

A review on optimization of machining performances and recent developments in electro discharge machining

Nahak

Gupta

2019

Manufacturing Rev.

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Electro discharge machining (EDM) is a popular unconventional machining process widely employed in die-making industries. Careful selection of process parameters such as pulse current, voltage, on and off time, etc. is essential for machining of hard and conductive materials using EDM. Previous researchers working in the area of EDM have extensively analyzed the machining performance through experimental study, modeling, and simulation and also by theoretical analysis. This article discusses the significant summary of the work performed by earlier researchers through a detailed literature survey. Relevant literature on EDM and impact of process parameters on performance measures such as surface quality, tool wear rate and material removal rate are reviewed. The challenge and limitation of EDM process are also highlighted in this article. It is observed that optimization of process parameters is essentially required for effective and economical machining. So, this article addresses the various issues related to EDM and also provides brief insight into some of the current generation applications of EDM process explored in various industries.

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Section: Hybrid Machining Process Using Edmmentioning

confidence: 99%

A review on optimization of machining performances and recent developments in electro discharge machining

Nahak

Gupta

2019

Manufacturing Rev.

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“…Ultrasonic vibrations have been suggested as a way to improve the flushing of the EDM process, especially for difficult-to-cut materials [23] and high aspect ratio blind holes [24]. This technique has shown promising increases in MRR [13], a higher process efficiency [25] and significant improvements in the obtainable surface quality in EDM finishing operations [26]. Although ultrasonic assisted EDM processes are widely used in industry, further investigation is still needed to help understand the ultrasonic vibration-assisted EDM process, dominant variables, process modelling and optimization, especially its application to deep micro/conventional drilling [27].…”

Section: State-of-the-art Flushing Approachesmentioning

confidence: 99%

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Goiogana

Elkaseer

2019

Materials

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This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

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“…In electrical discharge machining, for example, the vibrations improve debris removal from the sparking gap (Khatri et al, 2016). In the case of welding vibrations generate better material mixing and uniform grain growth and, therefore, improve mechanical and surface properties (Kumar et al, 2017). A decrease of the process force during deep drawing, due to ultrasonic vibration assistance, leads to an increase of the limiting drawing ratio (Huang et al, 2014).…”

Section: Introductionmentioning

confidence: 99%

Close-to-process strain measurement in ultrasonic vibration-assisted turning

Kimme

Hafez

Titsch

et al. 2019

J. Sens. Sens. Syst.

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Abstract. The application of ultrasonic vibration assistance in machining offers many benefits over conventional machining. In some machining processes, like the generation of geometrically defined microstructures by cutting, the interaction of the system components and the machining process can be particularly crucial with respect to the production result. Monitoring of ultrasonic vibration-assisted machining in terms of the in-process measurement of frequency and amplitude is currently realized by measurement inside the actuator; thus, measurement is presently undertaken relatively far away from the cutting process. In this paper an in-process measurement set-up based on strain gauges positioned close to the cutting edges is presented. It is used to investigate the induced vibration in the ultrasonic horn. Experiments on machine samples with and without ultrasonic vibration assistance are performed using the in-process measurement set-up described. The results of the strain gauges are analysed in comparison to internal feedback signal and surface measurements. The experiments show the high sensitivity of the measurement set-up presented and a huge gain of information compared with the conventional measurement approach. This enables improved controllability of the excited mode shapes as well as in-process adjustment of the ultrasonic vibration frequency and amplitude for the manufacturing of defined microstructures.

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Ultrasonic vibration–assisted electric discharge machining: A research review

Cited by 60 publications

References 56 publications

A review on optimization of machining performances and recent developments in electro discharge machining

A review on optimization of machining performances and recent developments in electro discharge machining

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Close-to-process strain measurement in ultrasonic vibration-assisted turning

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