Analysis and optimization of process energy consumption and environmental impact in electrical discharge machining of titanium superalloys

Zhang, Zhen; Yu, Haishen; Zhang, Yanming; Yang, Kai; Li, Wenyuan; Chen, Zhi; Zhang, Guojun

doi:10.1016/j.jclepro.2018.07.053

Cited by 58 publications

(15 citation statements)

References 20 publications

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“…Analysis indicates that the maximum machining rate M p decreases as M ex reduces because of the deterioration in the discharge of erosion products as the electrode is introduced in the material, and the number of working pulses is reduced [182, 183, 184].…”

Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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The productivity of electrical discharge machining (EDM) is relatively low owing to the natural laws of electrical erosion. Precise EDM demands uninterrupted control of the discharge gap and adjustment of process parameters. It is particularly critical for processing large workpieces with complex linear surfaces and for materials with threshold conductivities such as the new advanced ceramic nanocomposites Al2O3+TiC and Al2O3+SiCw+TiC(30–40%). In these cases, adequate flushing of erosion products is hampered by the geometry of the working space or by the small value of the required discharge gap, which does not exceed 2.2–2.5 μm. The methods of adaptive control in modern computer numerical control systems of EDM equipment based on measuring the electrical parameters in the working zone have been shown to be ineffective in the cases described above. This study aims to investigate the natural phenomena of material sublimation under discharge pulses for conductive ceramics and nanocomposites. The measured conductivities of the samples are higher than the percolation threshold. However, the question of machinability remains open owing to detected processing interruptions and poor quality of machined surfaces. New knowledge on EDM of conductive ceramics and nanocomposites can improve the final quality of the machined surfaces and productivity of the method by the introduction of advanced monitoring and control methods based on acoustic emissions. The manuscript presents an up-to-date overview and current state of the research on the subject area. The obtained morphology of the samples and discussion of the findings complete the experimental part of the study. The scientific basis for a new type of adaptive control system is provided. This can improve the effectiveness of parameter control for machining conductive ceramics and nanocomposites and contribute to an increase in the EDM performance for the most critical cases.

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Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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show abstract

“…The copper-manganese (70:30) combination has the greatest surface roughness value of 12.37 Ra. Other researchers have also reported on their research into surface roughness [ 118 , 119 , 120 , 121 , 122 , 123 ].…”

Section: Performance Measuresmentioning

confidence: 99%

Reviewing Performance Measures of the Die-Sinking Electrical Discharge Machining Process: Challenges and Future Scopes

et al. 2022

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The most well-known and widely used non-traditional manufacturing method is electrical discharge machining (EDM). It is well-known for its ability to cut rigid materials and high-temperature alloys that are difficult to machine with traditional methods. The significant challenges encountered in EDM are high tool wear rate, low material removal rate, and high surface roughness caused by the continuous electric spark generated between the tool and the workpiece. Researchers have reported using a variety of approaches to overcome this challenge, such as combining the die-sinking EDM process with cryogenic treatment, cryogenic cooling, powder-mixed processing, ultrasonic assistance, and other methods. This paper examines the results of these association techniques on various performance measures, such as material removal rate (MRR), tool wear rate (TWR), surface roughness, surface integrity, and recast layer formed during machining, and identifies potential gap areas and proposes a solution. The manuscript is useful for improving performance and introducing new resolutions to the field of EDM machining.

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“…They showed that almost no micropores and microcracks remains after processing in the argon medium [8]. Zhang et al proposed a magnetic eld-assisted EDM method and showed that the proposed method can reduce electrode wear and processing noise compared with conventional EDM [9].…”

Section: Introductionmentioning

confidence: 99%

Investigating the pulse short electric arc milling of Ti6Al4V alloy

Zhang

Zhou

et al. 2021

Int J Adv Manuf Technol

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In this study, characteristics of Ti6Al4V alloy are studied by pulse short electric arc milling (SEAM). In this regard, the in uence of SEAM parameters on the material removal rate (MRR), relative electrode wear rate (REWR) and surface integrity of Ti6Al4V is studied. A wide variety of processing parameters, including different voltages, frequencies, duty cycles, ushing pressures, electrode rotation speeds and electrode feed rates are considered in the investigation. Scanning electron microscope (SEM), energy dispersive spectrograph (EDS) and micro-hardness analysis are applied to analyze results. Moreover, a multichannel data acquisition system is used to measure gap voltage and gap current. Obtained results cover the variation of MRR, REWR, surface roughness (Ra), average re-solidi ed layer thickness and average heat-affected zone thickness with different processing parameters. Furthermore, the electrode surface morphology and chemical composition of the negative growth of REWR are studied. Based on the obtained results, the microstructure of the re-solidi ed layer and heat-affected zone of the workpiece cross-section is con rmed. This study provides a technological basis for the high-quality pulse SEAM technology of di cult-to-machine (DTM) materials to enter the semi-nishing eld.

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Analysis and optimization of process energy consumption and environmental impact in electrical discharge machining of titanium superalloys

Cited by 58 publications

References 20 publications

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Reviewing Performance Measures of the Die-Sinking Electrical Discharge Machining Process: Challenges and Future Scopes

Investigating the pulse short electric arc milling of Ti6Al4V alloy

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