Flushing Velocity Observations and Analysis during EDM Drilling

Kliuev, Mikhail; Baumgart, Christoph; Büttner, H.; Wegener, Konrad

doi:10.1016/j.procir.2018.08.210

Cited by 18 publications

(12 citation statements)

References 9 publications

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“…The EDM efficiency was also enhanced as the electrode rotation improved the flushing of the dielectric liquid out of the machining gap, resulting in a more uniform GC profile and lower incidence of recast layer. These findings are consistent with those of Kliuev et al [13]. They reported that insufficient flushing has a tendency to increase the recast layer thickness, and the effect is significant for high aspect ratios of hole diameter and hole depth.…”

Section: Characteristics Of Gc Of Edm With Side and Multi-aperture Flushingsupporting

confidence: 93%

“…Meanwhile, pulse on-time and electrical current influenced the deep hole profile [12]. Flushing plays a crucial role in the EDM process, since flushing removes debris from the machining gap and affects the EDM performance and deep hole characteristics [13]. Side flushing is conventionally used in EDM due to its simplicity and relatively efficient debris removal.…”

Section: Introductionmentioning

confidence: 99%

“…In [24], a response surface methodology based on a mathematical model was proposed to establish the relationship between EDM parameters (pulse on-time, gap voltage, and current) and material removal rate, gap size, roughness average, and electrode wear ratio. In [25], a response surface methodology based on the desirability function was utilized to Flushing plays a crucial role in the EDM process, since flushing removes debris from the machining gap and affects the EDM performance and deep hole characteristics [13]. Side flushing is conventionally used in EDM due to its simplicity and relatively efficient debris removal.…”

Section: Introductionmentioning

confidence: 99%

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Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Chuvaree

Kanlayasiri

2021

Metals

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This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

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Section: Characteristics Of Gc Of Edm With Side and Multi-aperture Flushingsupporting

confidence: 93%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Chuvaree

Kanlayasiri

2021

Metals

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“…One of EDD’s limitations during deep hole drilling is caused by the accumulation of debris at the bottom of the hole, which contributes to the wearing of the reinforced side electrode and secondary discharges (e.g., arcing and short circuits). An especially high concentration of eroded particles occurs in the corner of the drilled hole [16]. These phenomena lead to high process instability, defects on the internal surface of the holes, holes with poor shape accuracy (in terms of hole taper and hole dilation), excessive tool wear (at the side and the end), and a low machining speed [12,13,14,17,18,19].…”

Section: Introductionmentioning

confidence: 99%

“…Flushing with a high dielectric pressure can sweep the plasma channel and lead to a decrease in the material removal rate [21]. To improve flushing, several methods can be applied, including internal flushing (flushing through single-and multi-channel electrodes) [13,16], external flushing, suction, different electrode movements (rotary, planetary) [18], vibration-assisted methods [12], simultaneous flushing with a vacuum-assisted debris removal system [21,22], and the use of tool electrodes coated with a material of low electrical conductivity [14].…”

Section: Introductionmentioning

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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Modeling Electrical Discharge Machining of Deep Micro-Holes by Rotating Tool-Electrode

Nguyen

Волгин

Lyubimov

2021

Lecture Notes in Mechanical Engineering

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Flushing Velocity Observations and Analysis during EDM Drilling

Cited by 18 publications

References 9 publications

Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

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

Modeling Electrical Discharge Machining of Deep Micro-Holes by Rotating Tool-Electrode

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