Hydrodynamic arc moving mechanism in EDM of polycrystalline diamond

Wang, Xiangzhi; Guo, Hao; Wu, Ge; Ding, Sheng

doi:10.1080/10426914.2022.2032146

Cited by 6 publications

(3 citation statements)

References 29 publications

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“…Low flushing pressure can retain debris particles in the sparking gap, which could help disperse the discharge energy and reduce the surface roughness. Wang et al 122 investigated the dielectric flow rate on the surface roughness of PCD, and found that the surface roughness increases when the dielectric flow rate increases due to the reduced mixed-powder effect. Since sparking gap could affect the energy distribution ratio between the electrode and the dielectric, the sparking gap also can influence the surface roughness during the EDM process.…”

Section: Surface Roughnessmentioning

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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Section: Surface Roughnessmentioning

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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“…Yan et al [12] designed a novel pulse generator that generated high-frequency pulse signals with an off-time period, enabling the reionization of dielectric in the machining gap, minimizing damage to the machined surface of PCD. Wang et al [13,14] successfully manufactured a disk-shaped electrode and utilized the mobile arc generated by this electrode to expand the material removal range, significantly improving stability and processing performance.…”

Section: Introductionmentioning

confidence: 99%

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Guo,

Luo,

Liang

et al. 2024

Micromachines

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Die-sinking micro-electrical discharge machining (micro-EDM) is a potential method used to fabricate intricate structures without complex electrode motion planning and compensation. However, machining efficiency and poor discharge states are still bottlenecks. This study conducted a comparative investigation into the impact of ultrasonic vibration on die-sinking micro-EDM of polycrystalline diamond (PCD) and pure titanium (TA2). By adjusting discharge parameters, this study systematically evaluated the influence of ultrasonic vibration on these two materials based on discharge waveforms, motion trajectories, effective discharge counts and groove profiles. At an open-circuit voltage of 100 V, ultrasonic vibration promotes die-sinking micro-EDM of PCD. However, when the open-circuit voltage increases to 200 V, ultrasonic vibration exhibits inhibitory effects in general. Conversely, for TA2, ultrasonic vibration shows a promoting effect at both voltages, indicating the differences of ultrasonic vibration-assisted die-sinking micro-EDM on PCD and TA2. For PCD, ultrasonic cavitation improves the discharge gap environment, accelerating the removal of discharge debris. For TA2, due to its poor thermal conductivity, ultrasonic cavitation acts to break the arc, accelerating heat transfer. These research findings provide guidance for ultrasonic vibration-assisted die-sinking micro-EDM in industrial applications.

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“…The structural characteristics of the workpiece surface were revealed. Wang et al 19,20 developed a novel approach to the electrical arc machining of polycrystalline diamond with a rotating disk electrode by using the movement of discharging arcs, and studied the influence of hydrodynamic force on the arc movements and the performance of the moving electric arc EDM machining of PCD. Zhu 21 proposed a high-voltage excitation arc milling technology, which effectively increases the discharge gap of arc machining and improves the inter-pole discharge state by superimposing high-voltage pulses at both ends of the discharge electrode to influence the breakdown and arc-breaking effect of arc discharge.…”

Section: Introductionmentioning

confidence: 99%

Experimental research on short electric arc milling machining based on the mechanical-fluid coupling effect

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Short electric arc milling (SEAM) involves the complex coupling between the high-density heat output of the arc, the high-speed rotation of the tool electrode, and the high-pressure flushing fluid inside the tubular electrode. To improve the arc discharge utilization, this study investigates the effects of mechanical action, fluid action, and mechanical-fluid coupling action on the arc breakage of short arcs via experiments. It is found that the high-speed rotation of the electrode reduces the adsorption of the working fluid to the electrode surface, which can help to reduce the recast of molten metal on the workpiece surface and improve the surface quality. The coupling of the two makes a greater contribution to arc breaking and molten metal removal, while also improving the spatial continuity of the arc discharge. Moreover, after SEAM based on the mechanical-fluid coupling effect, the nickel-based alloy GH4169 is found to have lower surface roughness, lower tool electrode wear, a higher material removal rate, and a thinner recast layer.

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Hydrodynamic arc moving mechanism in EDM of polycrystalline diamond

Cited by 6 publications

References 29 publications

Electrical discharge machining of polycrystalline diamond: A review

Electrical discharge machining of polycrystalline diamond: A review

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium

Experimental research on short electric arc milling machining based on the mechanical-fluid coupling effect

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