Experimental modeling techniques in electrical discharge machining (EDM): A review

Hasan, Mohammad Mainul; Saleh, Tanveer; Sophian, Ali; Rahman, M.; Huang, Tao; Ali, Mohamed Sultan Mohamed

doi:10.1007/s00170-023-11603-x

Cited by 21 publications

(10 citation statements)

References 167 publications

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“…In literature review of EDM processes various empirical modeling techniques was found to understand the behavior of machining response when high current is applied on the machining zone, by taking in the account of heat effected zone, which is one of the main output response of the whole processes [16]. EDM processes use thermal energy to melt and evaporate materials.…”

Section: Numerical Modelingmentioning

confidence: 99%

Thermal modeling, simulation, and experimental validation of micro electric discharge machining of tungsten carbide (WC)

Ali,

Ali Khan,

Ali

2024

Eng. Res. Express

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Tungsten carbide is a material that is widely used in tools and dies applications due to its high hardness, excellent toughness, and wear resistance. However, machining this material using conventional methods can be very challenging due to its exceptional properties. In such cases, electrical discharge machining can be used as an alternative method for machining this material. The aim of this study is to examine the thermal properties of EDM of tungsten carbide, both through finite element modeling and experimental conditions. The study aims to evaluate the temperature distribution in tungsten carbide during EDM die sinking. This is accomplished by drilling 0.5mm diameter and 1mm deep micro holes using micro-drilling processes. Seven experiments were performed using an EDM die-sinking machine, and a 3D axis symmetrical model was created and simulated using the COMSOL Multiphysics heat transfer module. The temperature profile of tungsten carbide material during a single spark machining was obtained by considering only 30% of energy in the form of Gaussian distribution that gets transferred to the workpiece. The temperature profile of this model was then used to estimate the material removal rate. By comparing the numerical and experimental results, it was found that there was only a 4.8% average percentage error, indicating very close agreement between the numerical and experimental results. The findings suggest that the finite element method of the COMSOL Multiphysics heat transfer module can accurately predict and simulate the real-time results of EDM machining. These results could be useful for EDM machine operators for pre-estimating MRR and maximum temperatures before proceeding with the actual machining.

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Section: Numerical Modelingmentioning

confidence: 99%

Thermal modeling, simulation, and experimental validation of micro electric discharge machining of tungsten carbide (WC)

Ali,

Ali Khan,

Ali

2024

Eng. Res. Express

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Section: Introductionmentioning

confidence: 99%

“…A gas bubble is formed around the plasma channel, which undergoes implosional breakdown after the end of the electric discharge. This promotes the removal of the melted material [21][22][23][24][25][26][27][28][29]. The material removal phenomenon in the EDM process is based mainly on electricity, which is converted into thermal energy due to electrical discharges.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Nowicki,

Oniszczuk-Świercz,

Świercz

2024

Materials

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Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials.

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“…Despite being an energy-intensive process, almost no research has been carried out regarding the total energy consumption of WEDM and how the different machining parameters affect it. The authors in [11,12] provide an extensive account of research conducted on WEDM. However, they do not report any work related to the use of the total energy consumption of the process as a response to being analyzed and optimized.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Cutting Parameters for Energy Efficiency in Wire Electrical Discharge Machining of AISI D2 Steel

González-Rojas,

Miranda-Valenzuela,

Calderón-Najera

2024

Applied Sciences

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Improving energy efficiency in manufacturing processes is a critical global concern for the industry. Manufacturers strive to enhance energy efficiency across all manufacturing operations to remain competitive globally, aiming to reduce production times without compromising product quality. While there has been significant research characterizing energy efficiency and surface roughness in conventional processes like turning or milling, studies on unconventional manufacturing techniques are limited. This study focuses on optimizing a wire electrical discharge machining (WEDM) process to minimize energy consumption while maintaining surface roughness. Various cutting parameters, such as pulse on-time, pulse off-time, servo voltage, wire tension, wire speed, and wire voltage, were evaluated. Experiments were conducted using Taguchi’s methodology with a L27 orthogonal array, employing AISI D2 steel plates of 19 mm and 25 mm thickness as the machining material. The research identified that optimal parameters for reducing energy consumption and improving surface roughness included a pulse on-time of 10 s, pulse off-time of 11 s, servo voltage of 44 V, wire tension of 50 g-force, wire speed of 7 m per minute, and wire voltage of 9 volts. This combination led to an 8% reduction in energy consumption and a 1% enhancement in surface roughness compared to baseline values.

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Experimental modeling techniques in electrical discharge machining (EDM): A review

Cited by 21 publications

References 167 publications

Thermal modeling, simulation, and experimental validation of micro electric discharge machining of tungsten carbide (WC)

Thermal modeling, simulation, and experimental validation of micro electric discharge machining of tungsten carbide (WC)

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity

Optimization of Cutting Parameters for Energy Efficiency in Wire Electrical Discharge Machining of AISI D2 Steel

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