Influence of flushing on performance of EDM with bunched electrode

Li, Lei; Gu, Lixu; Xi, Xue-Cheng; Zhao, Wansheng

doi:10.1007/s00170-011-3357-8

Cited by 85 publications

(34 citation statements)

References 14 publications

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“…Furthermore, built-up edge (BUE) engrave at the tip of the tool, when this super-alloy is machined by using traditional machining processes. Therefore, EDM has been explored for the machining of this superalloy by using copper and brass electrodes [15).…”

Section: Introductionmentioning

confidence: 99%

Influence on machinability and form tolerance of Inconel 718 in Edm using different diameter multi hole Cu electrodes

Kumar

Dhanabalan²

2019

SN Appl. Sci.

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This research aims to examine the machinability and form tolerances in die sinking EDM for Ni-based superalloy with different diameter internally engraved hole of the multi-hole copper electrode. Manufacturing of superalloys with close tolerances is becoming a major area for primary research in defence and aerospace industries due to their particular characteristics. Therefore, this work focuses on an experimental analysis to improve the productivity and Material Removal Rate of Inconel-718 with close tolerances. The most dominating process constraints, viz. hole diameter of Multi-hole electrode (D), Peak current (I p ), Pulse on Time (T on ) and dielectric fluid pressure were selected as process constraints to conduct experimental trials. The Material Removal Rate, EWR and form tolerances were considered as output responses. The experimental outcomes were optimized by Taguchi analysis and multi-parametric optimization method GRA. A Fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, EWR, circularity and cylindricity with respect to changes in input parameters. Three MF's ('Trimf-triangular membership functions') were allocated to each input response, whereas five MF's were allocated to output responses. The Fuzzy model shows the 94.01% accuracy between the experimental values and the predicted values. From the results, it is concluded that the use of a multi-hole electrode leads to a higher rate of MRR. Moreover, the form tolerance deviation improves with the increment of T on value. The optimized parameters showed a considerable improvement in the process and will facilitate the aerospace and defence industries to improve the productivity of Inconel-718 with close tolerance.

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Section: Introductionmentioning

confidence: 99%

Influence on machinability and form tolerance of Inconel 718 in Edm using different diameter multi hole Cu electrodes

Kumar

Dhanabalan²

2019

SN Appl. Sci.

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“…These are of high engineering interest in applications as diverse as the combustion process of pulverized coal (Buhre et al, 2005), or the debris deposition during electrical discharge machining (Li et al, 2012). These applications involve not only the fluid force prediction on the particles themselves, but also require the computation of the heat exchange between the particles and the fluid to correctly determine e.g.…”

Section: Introductionmentioning

confidence: 99%

A numerical method for multiphysics simulations based on hierarchical Cartesian grids

Gadeschi

Schneiders

Meinke

et al. 2015

JFST

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We present a numerical method based on hierarchical Cartesian grids for the simulation of multiphysics problems, here in particular for the conjugate heat transfer between a fluid and a solid. The data structures developed for this simulation method allow to account for moving objects and are especially well suited for massive parallelization. The major problem of a suitable domain decomposition for a coupled fluid and heat conducting domain is solved by discretizing both domains on a joint hierarchical Cartesian mesh, where the individual cells can be marked according to the underlying physics, i.e. to be a fluid cell, a heat conducting cell or both. Individual solvers for the Navier-Stokes equations and the heat conduction equation are implemented which only operate on the Cartesian cells belonging to the fluid or solid subset of the joint hierarchical mesh. The solution strategy is validated against the analytical solution of the convective heat transfer between a heat-conducting solid flat plate and a laminar incompressible boundary layer. The applicability of the method for moving objects is then demonstrated by solving a conjugate heat transfer problem for a heated and moving cylinder in a laminar flow.

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“…In recent years, in order to improve the processing efficiency of 3D electrodes and reduce its production cycle, the bunched electrode was used to form the 3D electrodes [10,11]. Although the bunched electrode is mainly adopted to fabricate the largesized 3D electrodes, the basic idea can provide a useful reference for the fabrication of 3D micro-electrodes.…”

Section: Introductionmentioning

confidence: 99%

Laminated fabrication of 3D queue micro-electrode and its application in micro-EDM

Lei

Cheng

et al. 2015

Int J Adv Manuf Technol

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3D micro-electrode used in micro electrical discharge machining (micro-EDM) is difficult to be fabricated. Based on laminated object manufacturing (LOM) process, this paper superimposed multilayer 2D micro-structures together to fit out 3D micro-electrode and applied it in micro-EDM to process 3D micro-cavity mold. Firstly, 100-μm-thick Cu foils were cut by wire-electrical discharge machining (WEDM) to obtain multilayer 2D micro-structures, and then these 2D micro-structures were connected together to fit out 3D micro-electrode through vacuum pressure thermal diffusion welding. Secondly, under the effect of 80-V voltage, 0.2-MHz pulse frequency, 800-ns pulse width, and 4200-ns pulse interval, the 3D micro-electrode was applied in micro-EDM and 3D micro-cavity mold with high surface quality was obtained. Thirdly, in order to reduce the adverse impact of electrode wear on machining precision of 3D micro-cavity mold, 3D queue micro-electrode was used to process the same 3D micro-cavity mold, in which the first electrode is for rough machining and the others for fine machining. Finally, based on the above studies, two kinds of 3D queue micro-electrodes were fabricated, and the 3D micro-cavity molds with surface roughness Ra=0.48 μm were obtained through micro-EDM. Compared with the scanning 3D micro-EDM process, the 3D micro-cavity mold can be obtained through up and down reciprocating method of the 3D queue micro-electrode, featuring simple machining process and high efficiency.

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Influence of flushing on performance of EDM with bunched electrode

Cited by 85 publications

References 14 publications

Influence on machinability and form tolerance of Inconel 718 in Edm using different diameter multi hole Cu electrodes

Influence on machinability and form tolerance of Inconel 718 in Edm using different diameter multi hole Cu electrodes

A numerical method for multiphysics simulations based on hierarchical Cartesian grids

Laminated fabrication of 3D queue micro-electrode and its application in micro-EDM

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