Electric discharge milling: a state-of-the-art review

Mullya, Satish; Karthikeyan, G.; Ganachari, Vaibhav

doi:10.1007/s40430-021-03146-7

Cited by 12 publications

(7 citation statements)

References 142 publications

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“…The generalized model of the process should include [189]: discharge localization, plasma simulation, temperature distribution and material removal simulation from a single discharge and a series of discharges, gap flow simulation, object geometry simulation and its change, facility control, etc. It is required to create efficient algorithms for predicting tool wear and its compensation and monitoring [200]. The need to study the evolution of the melt pool for morphology, roughness, and surface quality during EDM is noted [84].…”

Section: Numerical Simulation Of the Edm Processmentioning

confidence: 99%

“…At the moment, numerical models are actively developed that take into account tool wear during machining [10,58,61,82,115,187,198,203,204,[206][207][208]. Tool wear is the main disadvantage of the process, which degrades the topography of the workpiece surface [200]. But so far it has not been possible to solve all the problems related to the possibility of predicting the final result of electro-erosive machining, taking into account the electrode wear and its compensation [187].…”

Section: Numerical Simulation Of the Edm Processmentioning

confidence: 99%

See 1 more Smart Citation

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

Kamenskikh,

Muratov,

Shlykov

et al. 2023

JMMP

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Electrical discharge machining (EDM) is a highly precise technology that not only facilitates the machining of components into desired shapes but also enables the alteration of the physical and chemical properties of workpieces. The complexity of the process is due to a number of regulating factors such as the material of the workpiece and tools, dielectric medium, and other process parameters. Based on the material type, electrode shape, and process configuration, various shapes and degrees of accuracy can be generated. The study of erosion is based on research into processing techniques, which are the primary tools for using EDM. Empirical knowledge with subsequent optimization of technological parameters is one of the ways to obtain the required surface quality of the workpiece with defect minimization, as well as mathematical and numerical modeling of the EDM process. This article critically examines all key aspects of EDM, reflecting both the early foundations of electrical erosion and the current state of the industry, noting the current trends towards the transition of EDM to the 5.0 industry zone in terms of safety and minimizing the impact of the process on the environment.

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Section: Numerical Simulation Of the Edm Processmentioning

confidence: 99%

Section: Numerical Simulation Of the Edm Processmentioning

confidence: 99%

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

Kamenskikh,

Muratov,

Shlykov

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

“…Similarly, these are being applied in micro-EDM [31], together with tungsten carbide and brass [32] or other materials based on those-for example, alloys such as cupronickel [33]. There are also other, less popular, materials used as electrodes to verify their possible application in the micro-EDM process, such as cermet [34], composites [35], materials based on polycrystalline diamond and boron-doped CVD-diamond [36], materials with additional coatings [37], and even carbon fibers [24,38].…”

Section: Typical Electrode Materials Selection Approachmentioning

confidence: 99%

Suggested Research Trends in the Area of Micro-EDM—Study of Some Parameters Affecting Micro-EDM

et al. 2021

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This paper provides an overall view of the current research in micro-electrical discharge machining (micro-EDM or µEDM) and looks into the present understanding of the material removing mechanism and the common approach for electrode material selection and its limitations. Based on experimental data, the authors present an analysis of different materials’ properties which have an influence on the electrodes' wear ratio and energy distribution during the spark. The experiments performed in micro-EDM conditions reveal that properties such as electron work function and electrical resistivity strongly correlate with the discharge energy ratio. The electrode wear ratio, on the other hand, is strongly influenced by the atomic bonding energy and was found to be related to the tensile modulus. The proposed correlation functions characterized the data with a high determination coefficient exceeding 99%.

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“…The main disadvantages of the die-sinking EDM are: a longer production time of the tool electrodes and necessity to machine mechanically shaped tool electrodes. In EDM milling, a simple cylindrical electrode is used as tool and the complex shaped parts can be generated by the movement of tool electrodes along a pre-de ned path [2]. EDM milling simpli es the manufacturing process of complex shaped parts and reduces the production time and cost of tool electrode because of the usage of a simple cylindrical tool.…”

Section: Introductionmentioning

confidence: 99%

EDM milling based on a 6-DOF serial robot

Yue

Chen

et al. 2022

Int J Adv Manuf Technol

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Aiming at the problems of insu cient exibility and limited size of workpiece in traditional EDM milling, an EDM milling method based on 6-DOF serial robot is proposed in this paper. To realize the rapid adjustment of machining gap, a tool electrode servo motion device was invented and installed at the end of a 6-DOF serial robot and a servo control strategy of tool electrode vertical trajectory fallback was proposed. Then, to achieve the controllable thickness of every layer in EDM milling based on 6-DOF serial robot, the servo control strategy of limited motion of the tool electrode on the basis of vertical servo control and a x-length compensation method to compensate the tool electrode wear were proposed. Finally, to verify the correctness and effectiveness of servo control strategy and wear compensation of tool electrode, the trapezoidal groove structures on the plane workpiece and cylindrical workpiece were machined by EDM milling based on 6-DOF serial robot, respectively. Also, to verify the machining ability of complex trajectory on the space surface of workpiece of EDM milling based on 6-DOF serial robot, three complex trajectories, such as EDM, Chinese character 'China' and 'Chinese knot', were designed and machined on the hemispherical workpiece with the radius of 38 mm. The feasibility and effectiveness of EDM milling technology based on 6-DOF serial robot were veri ed, which has great market application potential.

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Electric discharge milling: a state-of-the-art review

Cited by 12 publications

References 142 publications

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

Suggested Research Trends in the Area of Micro-EDM—Study of Some Parameters Affecting Micro-EDM

EDM milling based on a 6-DOF serial robot

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