Effects of Graphite and Boron Carbide Powders Mixed into Dielectric Fluid on Electrical Discharge Machining of SKD 11 Tool Steel

Mookam, Niwat; Sunasuan, Piyawan; Madsa, Tavee; Muangnoy, Phisith; Chuvaree, Suppawat

doi:10.1007/s13369-020-05156-4

Cited by 12 publications

(5 citation statements)

References 28 publications

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“…Alloys reinforced with particles tend to increase its hardness 37 which offers lower machining rate as compared with unreinforced alloys leads to lower MRR. 38 While machining the composites the material surrounds the reinforcing particles melts 39 and particles get detached from the surface. These materials enter inside the spark gap, 40 which further reduces the gap distance.…”

Section: Resultsmentioning

confidence: 99%

Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites

Parvez¹,

Abuthakeer

2021

ECS J. Solid State Sci. Technol.

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Composite materials are difficult to process under conventional machining techniques. When machined using such unconventional machining methods as the electric discharge process, the result is low machining efficiency due to the presence of reinforced particles. We sought to improve the machining characteristics of AA7050 hybrid composites by adding Al2O3 particles to the dielectric medium. Experiments were carried out using varying powder concentration, current, pulse on time, and weight percentage of composites and material removal rate (MRR), tool wear ratio, and surface roughness were recorded. Composites of different weight percentage were manufactured thru stir casting. SiCp and Al2O3p (mesh size 5 μm) were selected as reinforcing particles. Composites machined in powder mixed electric discharge machining (PMEDM) exhibit better MRR owing to the bridging effect. The modified plasma channel enhances surface quality because of the homogenous dispersal of discharge energy throughout the machined surface. Surface topography was analyzed with scanning electron microscopy. The specimen machined with EDM showed a re-melted layer and globules which were absent under PMEDM machining owing to which surface quality improves. The machining parameters were optimized using the TOPSIS technique and the specimen machined in PMEDM with parametric values 15 A current and 30 μs pulse on time offered the best machining characteristics.

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Section: Resultsmentioning

confidence: 99%

Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites

Parvez¹,

Abuthakeer

2021

ECS J. Solid State Sci. Technol.

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“…In the process of electroerosive grinding, electric discharges occur in the cutting zone during the breakdown of the interelectrode medium between the chips or metal surface and, when the chips slide along the bundle, discharges initiated by the explosive electroerosion of bridging elements, as well as discharges associated with the rupture of the electrical circuit in places where the chips are separated from the processed material at the end of micro-cutting [5]. All these electroerosive processes are associated with electrical discharges, which can have different conditions of initiation and f ormation and differ in their nature, parameters, and intensity of action on the electrodes [6].…”

Section: Introductionmentioning

confidence: 99%

Research of the dependence of geometric parameters of holes on electroerosive grinding modes with a changing polarity of electrodes

Strelchuk

Shelkovyi

Gutsalenko

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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In this paper are presented the results of electrical discharge diamond grinding with with difference polarities for processing various materials and calculates geometric parameters of erosion holes. The purpose of the study is to determine the volume of holes during electrical discharge diamond grinding using the mathematical method of planning experiments. The experimental plans is a combination of statistical theory and mathematical model, which is very useful in the modelling and analysing the technical problems. As a result of experimental studies, a mathematical model of the volume of holes from electrical modes of the process of electrical discharge diamond grinding was built. The mathematical formula of geometric parameters of holes obtained can be used to determine the volume of holes for different electrical quantities of discharge diamond grinding. It is found that the most significant factors that affect the geometric parameters of holes are the voltage of the igniting pulse and the pulse duration. The dependence of electrical parameters on the hybrid grinding process is investigated. There is a certain volume of holes, at which the discharge acts most efficiently, and the process performance is the most optimal. During the operation of the pulse generator, it is preferable to maintain a certain value of geometric parameters of holes, which results in an unhindered release of metal, since the effect of electrical erosion increases.

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“…The properties of the type of powder added to the dielectric fluid influence the performance. A comparison between two types of powders was made in [16], where JIS SKD11 was drilled using graphite and boron carbide (B4C) in the dielectric. The improvement in MRR is greater using graphite than boron carbide, probably due to the higher electrical conductivity of the graphite.…”

Section: Introduction Edm (Electrical Discharge Machiningmentioning

confidence: 99%

“…Regarding the quality aspects, the width and depth of the craters using powders in the dielectric are smaller; therefore, the surface finishing improves thanks to a higher number of sparks having lower energy [13,16]. In [10] the authors estimated that the roughness surface decreases in the range between 2.4 and 18.3% as a function of the process parameters.…”

Section: Introduction Edm (Electrical Discharge Machiningmentioning

confidence: 99%

“…The use of powders in the dielectric may change the chemical composition of the workpiece surface. In fact, the migration of the powder from the dielectric to the workpiece produces new chemical phases as a function of the powder type [16,20]. As a result, in some cases, the electrical chemical corrosion resistance of the workpiece material may improve, and the electrical conductivity may increase.…”

Section: Introduction Edm (Electrical Discharge Machiningmentioning

confidence: 99%

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Influence of 4-dodecylbenzenesulfonic acid as a surfactant on a graphite-based dielectric in powder mixed electric discharge machining

Pellegrini

Ravasio

Rosace

et al. 2022

Int J Adv Manuf Technol

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A recent trend in micro EDM is the addition of powders into the dielectric. The presence of powders helps to lower the dielectric breakdown voltage and therefore the discharge occurs early. As a result, the discharge energy is better distributed, resulting in a greater number of discharges, each with less energy. The main advantage of using this method is the improvement of both the process performance and surface finishing of the workpiece. A critical aspect of the implementation of this technology is in general the management of the powder. In fact, to obtain advantages during the machining, the powders should be maintained dispersed into the dielectric to avoid their aggregation. This paper aims to study the concentration of the powder and the surfactant in the dielectric fluid on micro EDM drilling performance. Titanium alloy was used as workpiece material, hydrocarbon oil as dielectric, graphite as powder and 4dodecylbenzenesulfonic acid as surfactant. The performance was evaluated considering the Material Removal Rate, the Tool Wear Ratio and the geometrical characteristics of the holes (overcut and taper rate). Graphite content positively affected both Material Removal Rate and Tool Wear Ratio; a larger spark gap was observed as well. The use of surfactant is required for mix stability but increasing its percentage generally reduces the effects of graphite and increases data dispersion as well.

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Effects of Graphite and Boron Carbide Powders Mixed into Dielectric Fluid on Electrical Discharge Machining of SKD 11 Tool Steel

Cited by 12 publications

References 28 publications

Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites

Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites

Research of the dependence of geometric parameters of holes on electroerosive grinding modes with a changing polarity of electrodes

Influence of 4-dodecylbenzenesulfonic acid as a surfactant on a graphite-based dielectric in powder mixed electric discharge machining

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Effects of Graphite and Boron Carbide Powders Mixed into Dielectric Fluid on Electrical Discharge Machining of SKD 11 Tool Steel

Cited by 12 publications

References 28 publications

Machining Characteristics of Al2O3 Powder Mixed Electric Discharge Machining of AA7050/SiCp/Al2O3p Hybrid Composites

Machining Characteristics of Al2O3 Powder Mixed Electric Discharge Machining of AA7050/SiCp/Al2O3p Hybrid Composites

Research of the dependence of geometric parameters of holes on electroerosive grinding modes with a changing polarity of electrodes

Influence of 4-dodecylbenzenesulfonic acid as a surfactant on a graphite-based dielectric in powder mixed electric discharge machining

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Product

Resources

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Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites

Machining Characteristics of Al₂O₃ Powder Mixed Electric Discharge Machining of AA7050/SiC_p/Al₂O_3p Hybrid Composites