A Review on Less Tool Wear Rate and Improving Surface Quality of Conductive Ceramic Composites by Spark EDM

Selvarajan, L.; Manohar, M.; Jayachandran, J. Amos Robert; Mouri, P.; Selvakumar, P.

doi:10.1016/j.matpr.2017.12.174

Cited by 9 publications

(8 citation statements)

References 14 publications

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“…As a result of the migration of materials and due to high temperature generated during machining, it was hypothesized that conductive metal carbides are formed on the machined surface, which cracks and peels off the machined surface due to the continuous sparking and thus facilitates the material removal. It is reported in the literature that the material removal mechanism of ceramics machined by assistive electrode method can be characterized by five distinguished phenomena, melting and evaporation, thermal spalling, decomposition and oxidation, fusion and vaporization, and electromagnetic and electrostatic force [ 53 ]. In this study, some of these characteristics were observed.…”

Section: Resultsmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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Non-conductive structural ceramics are receiving ever-increasing attention due to their outstanding physical and mechanical properties and their critical applications in aerospace and biomedical industries. However, conventional mechanical machining seems infeasible for the machining of these superior ceramics due to their extreme brittleness and higher hardness. Electro discharge machining (EDM), well known for its machining of electrically conductive materials irrespective of materials hardness, has emerged as a potential machining technique due to its noncontact nature when complemented with an assistive electrode technique. This paper investigates the material removal mechanism and effects of machining parameters on machining speed and dimensional and profile accuracies of features machined on zirconia toughened alumina (ZTA) ceramics using assistive electrode EDM. Our experimental results demonstrate that both increasing peak current and pulse on time improves the MRR, however, it also aids in generating thicker layer on machined surface. In addition, pulse interval time is crucial for the machining of nonconductive ceramics, as larger value might cause the complete removal of intrinsic carbon layer which may lead to non/sparking condition. Higher peak current increases circularity whereas short pulse on and pulse off time aid in increasing circularity due to rough machining. In addition, taperness is found to be regulated by the peak current and pulse on time. Overall, thermal cracking and spalling appear to be a dominating material removal mechanism other than melting and evaporation for the EDM of ZTA.

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Section: Resultsmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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“…It also shows that copper has intense wear comparing to aluminum and steel. Selvarajan et al (2018) have done a review on TWR and infers that cryogenic treatment, dielectric flushing and electrode rotation can reduce tool wear intensively.…”

Section: Literature Reviewmentioning

confidence: 99%

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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Purpose Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM). Design/methodology/approach This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining. Findings It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM. Originality/value The range of predicted results and the experimental results are in close agreement, authenticating the model.

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“…[30]. Tool geometry also has a good influence on EWR and is associated with the tool profile and also aspect ratio (length:diameter) [31].…”

Section: Tool Materialsmentioning

confidence: 99%

Electrical Discharge Machining: Vital to Manufacturing Industries

Khan¹,

Rao²

2019

IJITEE

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This paper presents an insight of state of art of electrical discharge machining process. In this process, material gets eroded from the workpiece because of chain of speedily repeating current discharges amidst twin electrodes, which are parted by dielectric fluid and made prone to a potential difference. This process offers various advantages over conventional process and finds wide applications in various industries. The information provided in this study will be very useful for the beginners to understand the basic fundamentals of unconventional EDM process

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A Review on Less Tool Wear Rate and Improving Surface Quality of Conductive Ceramic Composites by Spark EDM

Cited by 9 publications

References 14 publications

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Electrical Discharge Machining: Vital to Manufacturing Industries

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