An analysis of overcut variation and coupling effects of dimensional variable in EDM process

Chiang, Hao Ning; Wang, J. J. Junz

doi:10.1007/s00170-010-3145-x

Cited by 12 publications

(8 citation statements)

References 21 publications

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“…ROC is one of the important factors in analyzing EDM quality characteristics. Totally, there are three main factors having effects on ROC: 30–32 MRR: the higher MRR leads to placing more debris between the machined hole inner wall and tool electrode outer wall, so spark occurs between these particles and the workpiece. Hence, ROC increases. Plasma channel condition: the plasma channel can affect ROC in two ways.…”

Section: Doe Responses: Results and Discussionmentioning

confidence: 99%

Analysis of dry electrical discharge machining in different dielectric mediums

Fattahi

Baseri

2015

Proceedings of the Institution of Mechanical Engineers, Part E:

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Dry electrical discharge machining (EDM) is a modification of the oil EDM process in which the liquid dielectric is replaced by a gaseous dielectric. This study investigates the effects of different types of gas (air, nitrogen, and mixture of argon/air) on the machining characteristics of dry EDM of M35 workpiece material. A Taguchi L27 orthogonal array design was applied to investigate the effects of six control factors, including current, pulse on-time, duty factor, gas pressure, electrode rotational speed and specifically type of gas on machining responses, including material removal rate (MRR), surface roughness, and radial overcut. Also, the surface integrity was investigated in different dielectric mediums. Results show that the argon/air mixture can improve the MRR with respect to air and nitrogen. The best dimensional accuracy can be obtained by using nitrogen as the dielectric medium. Also, the machined surface with nitrogen has the fewest small drops and the microcracks in Aagon/air mixture is more than those air one. So, the argon/air mixture is the best dielectric with respect to nitrogen and air mediums for dry EDM of high-speed steel M35.

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Section: Doe Responses: Results and Discussionmentioning

confidence: 99%

Analysis of dry electrical discharge machining in different dielectric mediums

Fattahi

Baseri

2015

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…The reason behind this fluctuation could be the change in current characteristics due to the presence of relief angles that need further research. Since EDM is a complex phenomenon and the prediction of discharge current and other parametric behaviors is difficult [23], therefore due to the complex nature of the process slight variations in the machining results can be expected. Thus the involvement of multiple aspects (current characteristics, discharge phenomenon, relief angle, debris flushing, etc.)…”

Section: Effect Of Electrode Design On Machining Time (Mt)mentioning

confidence: 99%

“…As in the case of a 90 degree relief angle, it is possible that the behavior of the discharge current became erratic and the resulted taper of the hole reached a maximum value of 21.11 • . Since EDM is a complex phenomenon and the prediction of discharge current and other parametric behaviors is difficult [23], therefore further research is needed to understand the change in current performance when a relief angle of 90 • is provided. Hence, land with a relief of 90 • was the worst design in terms of the hole taper angle.…”

Section: Effect Of Electrode Design On Taper Angle (ø)mentioning

confidence: 99%

“…With respect to machining holes through EDM the difference between the designed geometry and machined geometry is very common [22]. It has been reported that the overcut especially in the case of hole making through EDM is highly difficult to forecast since there exists a complex and non-linear relationship of tool wear, tool diameter, and discharge parameters [23]. In a study presented in [24] the side over cut of the electric discharge machined (EDMed)hole has been significantly reduced by a varying electric field around the electrodes.…”

Section: Introductionmentioning

confidence: 99%

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Improving the Performance of EDM through Relief-Angled Tool Designs

et al. 2020

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Among the family of carbides, tungsten carbide (WC) and its variants have extensive use in numerous applications including cutting tools, dies, and many wear resistant parts. Such applications need machining of WC, which is famously considered as challenging due to high tool wear mainly in traditional machining. Sinking electric discharge machining (EDM) can be considered as a suitable alternate but the low machining rate of EDM, with conventional tool design, poses limitations. In this research, the conventional tool design is modified by providing relief angles to the tool electrodes. The relief-angled tool electrodes are first time introduced in this research to machine through holes. The role of the relief angle during EDM has been investigated in terms of six response characteristics, i.e., machining time, hole taper angle, radial overcut at the hole entrance, radial undercut at the hole exit, longitudinal tool wear, and roughness of inside hole surfaces. The performance of the relief-angled electrodes is found to be significantly better than the performance of conventional cylindrical tool. In addition to improvements in other responses, a 49% reduction in the machining time has been realized by the use of relief-angled electrode indicating a worthwhile contribution in the field of electric discharge machining.

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“…The change of the bottom and side overcuts, dimensions of electrode, dimensions of the hole and the positioning correctness of machine in the EDM process are studied by Chiang and Wang. 14 Janmanee and Muttamara 15 investigated the influence of EDM parameters on MRR , electrode wear rate (EWR) and tapered hole of martensitic stainless steel AISI 431.…”

Section: Introductionmentioning

confidence: 99%

Influence of machining parameters on the surface integrity in small-hole electrical discharge machining

Eyerci̇oğlu

Çakır

Göv

2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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This study investigates the effects of electro-discharge parameters on the surface integrity in small-hole drilling. Discharge current, pulse on-time and pulse off-time were chosen as variable parameters. The gap voltage, dielectric flushing pressure, electrode rotation, electrode polarity and capacitance were taken as constant. Material removal rate, surface roughness, average white layer thickness, overcut and taper were taken as outputs for this study. Experiments were performed on DIN 1.2080 (X210Cr12) cold working tool steel, and ∅2 mm single-hole brass electrodes were used. The experimental results indicate that a compromise solution is required in selection of the electrical discharge machining parameters (i.e. discharge current, pulse on-time and pulse off-time) to maintain machining stability (melting–evaporation and removal of debris). As the stability is maintained during the process, dimensional accuracy increases and a better finish can be obtained with a reasonable machining time.

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An analysis of overcut variation and coupling effects of dimensional variable in EDM process

Cited by 12 publications

References 21 publications

Analysis of dry electrical discharge machining in different dielectric mediums

Analysis of dry electrical discharge machining in different dielectric mediums

Improving the Performance of EDM through Relief-Angled Tool Designs

Influence of machining parameters on the surface integrity in small-hole electrical discharge machining

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