Enhancing Wire-EDM Performance with Zinc-Coated Brass Wire Electrode and Ultrasonic Vibration

Muttamara, Apiwat; Nakwong, Patittar

doi:10.3390/mi14040862

Cited by 4 publications

(3 citation statements)

References 25 publications

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“…EDM erodes the workpiece particles by forming regulated electric sparks among the work and tool material in the presence of suitable dielectric fluid [17,18]. The tool and work material need to be electrically conductive for machining through EDM [19,20]. The EDM process consists of several input factors that require balance to attain the desired outcome [21,22].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Chaudhari,

Khanna,

Patel

et al. 2023

Micromachines

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In the present study, a comprehensive parametric analysis was carried out using the electrical discharge machining of Ti6Al4V, using pulse-on time, current, and pulse-off time as input factors with output measures of surface roughness and material removal rate. The present study also used two different nanopowders, namely alumina and nano-graphene, to analyze their effect on output measures and surface defects. All the experimental runs were performed using Taguchi’s array at three levels. Analysis of variance was employed to study the statistical significance. Empirical relations were generated through Minitab. The regression model term was observed to be significant for both the output responses, which suggested that the generated regressions were adequate. Among the input factors, pulse-off time and current were found to have a vital role in the change in material removal rate, while pulse-on time was observed as a vital input parameter. For surface quality, pulse-on time and pulse-off time were recognized to be influential parameters, while current was observed to be an insignificant factor. Teaching–learning-based optimization was used for the optimization of output responses. The influence of alumina and nano-graphene powder was investigated at optimal process parameters. The machining performance was significantly improved by using both powder-mixed electrical discharge machining as compared to the conventional method. Due to the higher conductivity of nano-graphene powder, it showed a larger improvement as compared to alumina powder. Lastly, scanning electron microscopy was operated to investigate the impact of alumina and graphene powder on surface morphology. The machined surface obtained for the conventional process depicted more surface defects than the powder-mixed process, which is key in aeronautical applications.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Chaudhari,

Khanna,

Patel

et al. 2023

Micromachines

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show abstract

“…Ultrasonic-assisted welding is one of the important applications of ultrasonic technology with a high frequency (15 kHz to 40 kHz) and a low amplitude [2]. Different kinds of ultrasonic vibration-assisted machining processes, such as milling [3,4], turning [5,6], grinding [7,8], drilling [9,10], deburring [11,12], diamond machining (cutting) [13,14], electrical discharge machining (EDM) [15,16], abrasive water jet machining [17], hybrid laser-and ultrasonic-assisted machining [18,19], and surface finishing [20][21][22], etc., have been developed in recent years. The materials processed by the ultrasonic-assisted machining processes [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22], in general, can be classified as brittle materials, hard-machining metallic materials, composite materials, and non-metallic materials, etc.…”

Section: Introductionmentioning

confidence: 99%

“…The zirconia responses to edge chipping damage induced in conventional and ultrasonic vibration-assisted diamond machining are presented in [14]. Wire-EDM performance has been enhanced with zinc-coated brass wire electrode and ultrasonic vibration [15]. The research on ultrasonic vibration-assisted electrical discharge machining SiCp/Al composite has been presented in [16].…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic-Assisted Surface Finishing of STAVAX Mold Steel Using Lab-Made Polishing Balls on a 5-Axis CNC Machining Center

Shiou,

Pan,

Ding

et al. 2023

Materials

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The inconvenience of conventional wool ball polishing is that the surface finishing process should be equipped with a slurry container. The main objective of this research is to develop an ultrasonic-assisted surface finishing process for STAVAX mold steel on a 5-axis CNC machining center, by using new lab-made rubber polishing balls containing the abrasive aluminum oxide instead of the traditional wool ball polishing. In total, five types (type A to type E) of new rubber-matrixed polishing balls with a composite of nitrile butadiene rubber (NBR), an abrasive of aluminum oxide, and an additive of silicon dioxide have been developed. The performance of the composites with different grain sizes (0.05 μm to 3 μm) and concentrations of the abrasive of aluminum oxide have been investigated. The effects of multiple polishing passes on the surface roughness improvement for the lab-made polishing balls have also been investigated in this study. A surface roughness of Ra 0.027 μm on average was achieved by using the multiple polishing process of E-C-B-A. The volumetric wear of the lab-made polishing balls, using ultrasonic vibration-assisted polishing, can be improved from about 12.64% (type A) to 65.48% (type E) compared with the non-vibration-assisted polishing. The suitable combination of the ultrasonic vibration-assisted polishing parameters were an amplitude of 10 μm, a frequency of 23 kHz, a spindle speed of 5000 rpm, a feed rate of 60 mm/min, a stepover of 20 μm, a penetration depth of 180 μm, and a polishing pass of E-C-B-A, based on the experimental results. The surface roughness improvement on a test carrier with a saddle surface has also been presented by using the ultrasonic vibration-assisted polishing with the lab-made polishing balls.

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A Review on Multi-objective Optimization Techniques of Wire Electrical Discharge Machining

Pendokhare,

Chakraborty

2024

Arch Computat Methods Eng

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Enhancing Wire-EDM Performance with Zinc-Coated Brass Wire Electrode and Ultrasonic Vibration

Cited by 4 publications

References 25 publications

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Experimental Investigations of Using Aluminum Oxide (Al2O3) and Nano-Graphene Powder in the Electrical Discharge Machining of Titanium Alloy

Ultrasonic-Assisted Surface Finishing of STAVAX Mold Steel Using Lab-Made Polishing Balls on a 5-Axis CNC Machining Center

A Review on Multi-objective Optimization Techniques of Wire Electrical Discharge Machining

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