Electrical Discharge Machining of PCD in Ultrapure Water

Yanagida, Daisuke; Minami, Hisashi; Watanabe, Kôji

doi:10.1016/j.procir.2016.02.288

Cited by 12 publications

(4 citation statements)

References 3 publications

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“…A decrease in linear tool wear took place for higher values of discharge voltage and a longer pulse time (Figure 11). Based on the results analysis in [5,34], the application of deionized water produced a decrease in linear tool wear with a simultaneous increase in the process’s performance. In [35], the results analysis revealed that a sufficiently high value of applied discharge voltage and a long pulse time enabled material to be removed by electrochemical dissolution and electrical discharges in a single impulse.…”

Section: Resultsmentioning

confidence: 99%

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Machno

2019

Materials

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Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their structure. The quality of the holes significantly affects the cooling process of the elements. However, it is challenging to machine materials by conventional methods. When machining a hole with a high aspect ratio, the major problem is effective flushing of the machining area, which can improve the hole’s surface integrity and dimensional accuracy. Consequently, the electro-discharge drilling (EDD) process is good alternative for this application. This paper presents the results of an analysis of the EDD of Inconel 718 alloy. An experiment was conducted to evaluate the impact of process parameters (pulse time, current amplitude, and discharge voltage) on the process’s performance (linear tool wear, taper angle, drilling speed, the hole’s aspect ratio, and surface roughness (Ra and Rz)). The results show that EDD provides us with the possibility to drill holes with an aspect ratio greater than 10:1. The results also demonstrate that holes with an aspect ratio greater than 10:1 and a small taper angle value have a significantly decreased quality of internal surface, especially at the bottom of the hole. This indicates that an insufficient amount of debris is removed from the bottom of the hole.

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Section: Resultsmentioning

confidence: 99%

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Machno

2019

Materials

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“…It was also found that the concentration of crack was more on the wall, which significantly varied with machining condition (i.e., with current, voltage, and pulse duration) Water and air [61] Steel PCD Polycrystalline diamond (PDC) possesses poor machining efficiency during EDM operation, but while machined with water as a dielectric, impressive MRR was observed. Moreover, the sharpening process of PCD with steel as an electrode gave suitable value of MRR and surface integrity along with less electrode consumption, which was better than kerosene or EDM oil [38] Water-aqueous solution of calcium chloride…”

Section: Tungsten Carbide Becumentioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

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Low removal rate, high power consumption, and dependency on conventional fuels (kerosene as a dielectric) are some premier issues that keep the sustainability index of EDM low, though it has huge acceptability and popularity mostly in aviation sectors and biomedical instrumentation to machine some extensively hard ferrous and nonferrous metal/metal alloys. Besides these, the thermal agitation inside the fusion/machining zone partially burns the dielectrics and tool-workpiece-metal, which evolve some oxides/monoxides. These evolved gases promote an unhygienic breathing atmosphere, which is very much harmful to the operator's health. Sometimes because of inadequate flushing pressure and velocity, carbon particles deposited inside the crater makes the spark unstable and releases carbon monoxide when the temperature exceeds its melting point. According to ISO 14000, every manufacturing process must be comprised of the sustainability criteria, which maintains a compromised balance between the economic, environmental, and social aspects, including the issue of the operator's health. But in real practices, it is very tough to maintain a stoichiometric balance between all these constraints. The article intensely focuses on the issue of emergence of gases during machining and tries to promote the utility of some alternative vegetable oil-based dielectrics, which are experimentally justified as a potent alternative of conventional kerosene. Apart from these, it includes some comparative talks on dielectric nature and their impacts on the responses and surface properties. Finally, this article highlights some compromise solutions which are probably capable of mitigating the hurdles to some extent, so that the sustainable machining can be encouraged in real sense.

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“…It was found that the ultrapure water dielectric could weaken the electrochemical corrosion, especially when the fluid was flowing. 97 Air-mist and air dielectrics were investigated in wire EDM and die-sink EDM to reduce the electrochemical corrosion effect further and improve surface quality. It was found that surface roughness and thermal damage layer were reduced when using dry or near dry EDM methods.…”

Section: Non-electrical Factorsmentioning

confidence: 99%

Electrical discharge machining of polycrystalline diamond: A review

Wang

Guo

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Owing to its ultra-hardness and exceptional wear resistance, polycrystalline diamond (PCD) is widely used in numerous applications such as bearing, nozzle, metal cutting, oil and gas, and hard rock mining. However, the hardness of diamond means PCD products are incredibly difficult to manufacture. Electrical discharge machining (EDM) is one of the most effective non-traditional methods used for machining PCD materials, although the unique composite structure and low electrical conductivity of PCD lead to low machining efficiency. This paper presents an overview of the methods and newly emerged state-of-the-art technologies to improve material removal rate and surface quality as well as the mechanisms behind these methods. Literature analysis shows that efficiency improvement could be achieved by increasing energy utilization and the sparking gap in EDM. The utilization of discharge energy is highly sensitive to the expansion of single discharge sparks. Further improvement in machining efficiency could be achieved by enhancing discharge expansion and explosive force through changing processing forms, dielectric, electrode shape, and power generator in the future. To provide a comprehensive insight of the machinability of PCD, EDM processes of using PCD as tool electrodes to machine other materials to improve machining performance are also discussed.

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Electrical Discharge Machining of PCD in Ultrapure Water

Cited by 12 publications

References 3 publications

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Electrical discharge machining of polycrystalline diamond: A review

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