Improvement of EDM performance in high-aspect ratio slot machining using multi-holed electrodes

Flaño, O.; Ayesta, I.; Izquierdo, B.; Sánchez, J.A.; Zhao, Yonghua; Kunieda, Masanori

doi:10.1016/j.precisioneng.2017.08.014

Cited by 33 publications

(10 citation statements)

References 14 publications

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“…The main advantage of these non-conventional technologies is that they are able to achieve tough dimensional accuracy and excellent finishing surfaces working on complex geometrical cavities where milling has no accessibility [ 17 , 18 ]. However, these technologies offer low material removal rates, translated to higher manufacturing time and costs [ 19 ].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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Thermoresistant superalloys present many challenges in terms of machinability, which leads to finding new alternatives to conventional manufacturing processes. In order to face this issue, super abrasive machining (SAM) is presented as a solution due to the fact that it combines the advantages of the use of grinding tools with milling feed rates. This technique is commonly used for finishing operations. Nevertheless, this work analyses the feasibility of this technique for roughing operations. In order to verify the adequacy of this new technique as an alternative to conventional process for roughing operations, five slots were performed in Inconel® 718 using flank SAM and flank milling. The results showed that flank SAM implies a suitable and controllable process to improve the manufacture of high added value components made by nickel-based superalloys in terms of roughness, microhardness, white layer, and residual stresses.

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Section: Introductionmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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“…Figure 3 shows the image of the gas film formation by using a tapered tungsten carbide (WC) electrode with a diameter of 249 μm that is arranged based on the tool immersion depth. The tapered tool electrode design (i.e., complex shaped electrodes [ 15 ]) is able to help to drill deep and narrow cavities [ 16 ] and stabilize the machining process [ 17 ]. A tapered tool electrode was clamped on the chuck and employed in the experiments to increase the consistency of spark generation and to focus the discharges on a concentrated region.…”

Section: Experimental Setup and Methodsmentioning

confidence: 99%

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision

2018

Materials

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Spark-assisted chemical engraving (SACE) is a non-traditional machining technology that is used to machine electrically non-conducting materials including glass, ceramics, and quartz. The processing accuracy, machining efficiency, and reproducibility are the key factors in the SACE process. In the present study, a machine vision method is applied to monitor and estimate the status of a SACE-drilled hole in quartz glass. During the machining of quartz glass, the spring-fed tool electrode was pre-pressured on the quartz glass surface to feed the electrode that was in contact with the machining surface of the quartz glass. In situ image acquisition and analysis of the SACE drilling processes were used to analyze the captured image of the state of the spark discharge at the tip and sidewall of the electrode. The results indicated an association between the accumulative size of the SACE-induced spark area and deepness of the hole. The results indicated that the evaluated depths of the SACE-machined holes were a proportional function of the accumulative spark size with a high degree of correlation. The study proposes an innovative computer vision-based method to estimate the deepness and status of SACE-drilled holes in real time.

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“…Abrasive processes need to be considered as a possible alternative for IBRs manufacturing. There are some non-conventional abrasive technologies (abrasive flow machining, magnetic abrasive finishing or magneto-rheological abrasive flow finishing) characterized by their good performance for complex geometrical cavities with limited accessibility for conventional processes, achieving great dimensional accuracies and finishing surface quality requirements [61]. However, at the same time, these processes present low material removal rates, implying less productivity in terms of machining time and costs [62].…”

Section: Super Abrasive Machining (Sam)mentioning

confidence: 99%

Manufacturing Processes of Integral Blade Rotors for Turbomachinery, Processes and New Approaches

et al. 2020

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Manufacturing techniques applied to turbomachinery components represent a challenge in the aeronautical sector. These components are commonly composed of high resistant super-alloys; in order to satisfy the extreme working conditions, they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), they usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. Thermoresistant superalloys present many challenges in terms of machinability what leads to find new alternatives to conventional manufacturing processes. In order to face this issue, this work presents a review of the last advances for IBR manufacturing and repairing processes.

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Improvement of EDM performance in high-aspect ratio slot machining using multi-holed electrodes

Cited by 33 publications

References 14 publications

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision

Manufacturing Processes of Integral Blade Rotors for Turbomachinery, Processes and New Approaches

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