Discharge energy based optimisation of sinking EDM of cemented carbides

Petersen, Timm; Küpper, U.; Klink, Andreas; Herrig, T.; Bergs, Thomas

doi:10.1016/j.procir.2022.03.113

Cited by 7 publications

(4 citation statements)

References 11 publications

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“…For cemented carbides, it has been proposed [11] to use needle type discharges in order to optimise production with both objectives in mind. It has been shown that this approach can be applied successfully for fine and ultra-fine grained cobalt cemented tungsten carbides [12]. It could also be seen that the surface roughness changed from one machining step to the other.…”

Section: Introductionmentioning

confidence: 90%

Coefficient of friction of cemented carbides machined by sinking EDM

Petersen

2023

Materials Research Proceedings

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Abstract. Cemented carbides possess properties that predestine them as a durable tool. However, these properties hinder conventional machining, which is why Electrical Discharge Machining (EDM) is a promising alternative. Three different EDMed cemented carbides were compared with a ground surface in a pin-on-disk test setup. They were evaluated under dry and lubricated conditions with two distinct antibody materials. The tests did not reveal a correlation between the surface roughness of the cemented carbide pins and the coefficient of friction. However, some test sets yielded very different results, which is why particular considerations should be made with new sliding compositions.

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Section: Introductionmentioning

confidence: 90%

Coefficient of friction of cemented carbides machined by sinking EDM

Petersen

2023

Materials Research Proceedings

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“…Der prozentuale Anteil des Energieeintrages in das Werkstück E WS kann je nach Anwendungsfall zwischen 1,0 % und 65,5 % liegen [9]. Auch wenn die Entladeenergie E e nicht linear proportional zum Abtrag und Verschleiß ist, ist die Analyse der Signalformen von Spannung U und Strom I und letztendlich der Entladeenergie E e , eine etablierte Methode zur Prozessbewertung und findet in vielen Arbeiten Einsatz [5][6][7][8][9][10][11].…”

Section: Energiedissipation In Der Funkenerosionunclassified

“…Die Analyse dieser Signale kann durch Klassifizierung Auskunft über die Qualität und Anzahl der abtragwirksamen Entladungen im Vergleich zu entarteten Entladeerscheinungen wie Kurzschlüssen, Lichtbögen oder auch Leerläufen geben. Dies wiederum eröffnet diverse Möglichkeiten der Prozessoptimierung [4][5][6][7].…”

Section: Introductionunclassified

Echtzeit-Energieüberwachung in der Funkenerosion/Real-time energy monitoring in electrical discharge machining – Advanced software practices for signal analysis and classification

Uhlmann,

Polte,

Yabroudi

et al. 2023

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Ein großes Optimierungspotenzial der Funkenerosion liegt in den Energien der einzelnen Entladungen verborgen. Eine vektorielle Bestimmung der Entladedauern und die darauf basierende Energieberechnung sowie Klassifizierung erlauben es, die Entladeenergien, Entladungsarten und -dauern in Echtzeit zu überwachen und zu analysieren. Möglich wird dies durch ein Multiprocessing-Erzeuger-Verbraucher-Schema, welches überdies eine Visualisierung und Auswertung der Messdaten erlaubt. A large optimization potential of electrical discharge machining is hidden in the energies of individual discharges. A vector-based determination of discharge durations and the resulting energy calculation and classification allow for real-time monitoring and analysis of discharge energies, discharge types, and discharge durations. This is made possible by a multiprocessing producer-consumer scheme, which also allows for visualization and evaluation of measurement data.

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“…already developed a pulse discriminator, not just for the basic four pulse type classification of normal sparks, short circuits, arcs and open circuits but also for the subdivision of fifteen pulse types, e.g., ignition-delay-free discharges or less effective normal spark discharges [67]. Other authors used thresholds [15,[69][70][71][72][73][74], discharge-energybased approaches [68,75] or field programmable gate arrays (FPGAs) for real-time signal processing [76,77]. NIRALA AND SAHA observed the distribution of energy in micro-ED drilling while studying online responses, such as the pulse frequency and the pulse type density, as well as offline responses, such as the MRR or volume removal per discharge.…”

Section: State Of the Artmentioning

confidence: 99%

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

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The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.

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Discharge energy based optimisation of sinking EDM of cemented carbides

Cited by 7 publications

References 11 publications

Coefficient of friction of cemented carbides machined by sinking EDM

Coefficient of friction of cemented carbides machined by sinking EDM

Echtzeit-Energieüberwachung in der Funkenerosion/Real-time energy monitoring in electrical discharge machining – Advanced software practices for signal analysis and classification

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

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