Abstract:Material removal in micro-electro-discharge machining (μEDM) is subjected to electrical breakdown within the dynamic discharge gap. The nature (shape, size, and frequency) of the waveforms (voltage and current) in the discharge gap of μEDM is unpredictable resulting in nonisoenergetic pulses. The effect of these uncertainties in the nature of the pulses with respect to machining progress is analyzed at various responses such as pulse frequency, pulse density, material removal rate, and volume removal per disch… Show more
“…Bissacco et al [ 82 ] found the pulses not to be isoenergetic and claimed that it is crucial to consider non-contributing discharge pulses in the pulse counting method. Nirala et al [ 87 ] and Raza et al [ 88 ] corroborated this claim by conducting a detailed analysis of the discharge pulses, as illustrated in Fig. 23 (a–c).…”
Section: Online Tool Wear Compensationmentioning
confidence: 69%
“… Fig. 23 Pulse events of voltage and current in μEDM drilling at (a) the start, (b) the middle, and (c) the finish [ 87 ]. …”
“…Bissacco et al [ 82 ] found the pulses not to be isoenergetic and claimed that it is crucial to consider non-contributing discharge pulses in the pulse counting method. Nirala et al [ 87 ] and Raza et al [ 88 ] corroborated this claim by conducting a detailed analysis of the discharge pulses, as illustrated in Fig. 23 (a–c).…”
Section: Online Tool Wear Compensationmentioning
confidence: 69%
“… Fig. 23 Pulse events of voltage and current in μEDM drilling at (a) the start, (b) the middle, and (c) the finish [ 87 ]. …”
“…Additionally, it leads to the freezing of abnormal discharges by proper debris evacuation from the discharge gap. However, abnormal discharges due to debris accumulation are significant for increased tool wear in μEDM [28]. As a result, there is less possibility for debris re-solidification, due to its rapid cooling, on the machined tool plate surface in Reverse-μEDM.…”
Section: Reverse-µedm Using Optimal Tool Platementioning
This paper focuses on the fabrication of high-quality novel products using a µEDM process variant called Reverse-µEDM. The tool plate required for the Reverse-µEDM is fabricated using Nd: YAG-based laser beam micromachining (LBµM) at the optimized process parameters. The Grey relation analysis technique is used for optimizing LBµM parameters for producing tool plates with arrayed micro-holes in elliptical and droplet profiles. Titanium sheets of 0.5 mm thickness were used for such micro-holes, which can be used as a Reverse-µEDM tool. The duty cycle (a combination of pulse width and frequency) and current percentage are considered as significant input process parameters for the LBµM affecting the quality of the micro-holes. A duty cycle of 1.25% and a current of 20% were found to be an optimal setting for the fabrication of burr-free shallow striation micro-holes with a minimal dimensional error. Thereafter, analogous protrusions of high dimensional accuracy and minimum deterioration were produced by Reverse-µEDM using the LBµM fabricated tool plates.
“…Here, the sampling rate was 100 MS, so the change in time is taken to be 0.1. As discharge energy (E) [7] is given by (6): (6) The energy plot shown in the fourth (IV) plot of the Fig. 6 is given a curve Gaussian curve fitting for better visualization of the nature of energy discharge.…”
Owing to the non-isoenergetic nature of discharge pulses in resistance-capacitance (RC) based micro-EDM (µEDM), the volume of micro-crater generated by each pulse varies significantly. This fact has driven the researchers in this work to propose an electrothermal principle-based analytical model to approximate dimensional (diameter and depth) accuracies of such micro-craters. An investigation has been done to robustly apprehend the nature of energy distribution during single discharge micromachining in µEDM. The study gradually substantiates the theoretical nature of energy distribution during a single discharge. The predicted nature of energy distribution helps in comprehending the volume removed from the workpiece, energy loss, and machining efficiency.
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