A study of electrode wear ratio on EDM of Ti-6AL-4V with copper-tungsten electrode

Zainal, Nurezayana; Zain, Azlan Mohd; Sharif, Safian

doi:10.1051/matecconf/20167801013

Cited by 4 publications

(6 citation statements)

References 12 publications

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“…The authors concluded that the Ni-Ti alloys can be commercially machined by EDM using a copper-tungsten electrode. When die-sinking Ti-6Al-4V with copper-tungsten electrodes, Zainal et al [92] concluded that discharge current and duration had the highest effect on tool wear ratio. Copper-tungsten electrodes were also found to improve MRR when using vibration-assisted EDM of Ti-6Al-4V [43].…”

Section: Edm Of Metals and Their Alloysmentioning

confidence: 99%

Materials used for sinking EDM electrodes: a review

Czelusniak

Higa

Torres

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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Over the years, sinking electrical discharge machining has become one of the most important production technologies to manufacture very accurate three-dimensional complex components on any electrically conductive material. This article reports a literature review on the diversity of conventional and non-conventional materials that are used or have potential to be used as EDM electrodes. In addition, additive manufacturing of EDM electrodes are also reviewed. Keywords Sinking electrical discharge machining • EDM electrodes • Materials for electrodes • Additive manufacturing List of symbols î e Discharge current (A) t 0 Pulse interval time (μs) p in Dielectric inlet pressure (Pa) t d Ignition delay time (μs) t e Discharge duration (μs) t i Pulse duration (μs) t p Pulse cycle time (μs) u e Discharge voltage (V) û i Open-circuit voltage (V) V e Electrode wear rate (mm 3 /min) V w Material removal rate (mm 3 /min) W e Discharge energy (J)

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Section: Edm Of Metals and Their Alloysmentioning

confidence: 99%

Materials used for sinking EDM electrodes: a review

Czelusniak

Higa

Torres

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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“…Macedo et al (2019) in their research have studied the application of the theoretical model and numerical simulation which clearly shows that the plasma physics technique is a tool to estimate the power deposition on the anode workpiece in DEDM. Zainal et al (2016) proved that the electrode wear rate is proportional to current, voltage, as higher current and voltage will generate a stronger spark, which produces more thermal energy. This study also reveals that electrode wear progressively increases after the decrement of the cycle of time.…”

Section: Literature Reviewmentioning

confidence: 99%

“…The effect of dielectric on quality of machining and measurement of response variables such as TWR and MRR. The review indicates that although, several works have been reported till now to enhance the performance of considering TWR as the response (Macedo et al , 2019; Zainal et al , 2016; Muthuramalingam and Mohan, 2015; Dodun et al , 2015) However, a report that evaluates the simultaneous effect of DEDM and NDEDM process is extremely scarce in the literature. It is also observed that during the machining process, the effect of dielectric fluid on the plasma channel formation process has not been given adequate importance.…”

Section: Literature Reviewmentioning

confidence: 99%

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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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“…The term "non-traditional machining" refers to the removal of surplus material utilizing a variety of methods, including electrical, chemical, thermal, and mechanical energy [3]. Electrically conductive materials with high levels of durability and hardness are often machined using the EDM process [1,4,5]. Besides, EDM processes are adaptable since they may continue to operate independently for extended periods [2,6].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Electrical Discharge Machining Process by Metaheuristic Algorithms

Zainal,

Sithambranathan,

Farooq Khattak

et al. 2024

QAJ

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Because of its versatility and ability to work with difficult materials, Electrical Discharge Machining (EDM) has become an essential tool in many different industries. It can produce precise shapes and intricate details. EDM has transformed fabrication processes in a variety of industries, including aerospace and electronics, medical implants and surgical instruments, and the shaping of small components. Its capacity to machine undercuts and deep cavities with little material removal makes it ideal for producing complex geometries that would be challenging or impossible to accomplish with conventional machining techniques. Several attempts have been carried out to solve the optimization problem involved in the EDM process. This paper emphasizes optimizing the EDM process using three metaheuristic algorithms: Glowworm Swarm Optimization (GSO), Grey Wolf Optimizer (GWO), and Whale Optimization Algorithm (WOA). The study's outcome showed that the GWO algorithm outperformed the GSO and WOA algorithms in solving the EDM optimization problem and achieved the minimum surface roughness value of 1.7593µm.

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A study of electrode wear ratio on EDM of Ti-6AL-4V with copper-tungsten electrode

Cited by 4 publications

References 12 publications

Materials used for sinking EDM electrodes: a review

Materials used for sinking EDM electrodes: a review

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

Optimization of Electrical Discharge Machining Process by Metaheuristic Algorithms

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