Influence of micro-electrical discharge machining parameters on the surface morphology of the nickel-coated electrode

Siva, M.; Arunkumar, N.; Subramanian, M.; Elakkiyadasan, R.

doi:10.1080/10426914.2022.2105869

Cited by 12 publications

(6 citation statements)

References 31 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…From the SEM image, EWR is more on the bottom section of the brass tube. e effects have good agreement with the machining of D2 steel [25].…”

Section: Analysis Of the Edge Of The Toolsupporting

confidence: 58%

“…When compared to an uncoated electrode, the size of the crater is smaller in the coated tool, indicating that the tool life is increased. e result supported for justification as it was used for machining D2 steel [25].…”

Section: Surface Analysis Of the Coated Toolmentioning

confidence: 71%

“…is results in a low MRR for the uncoated electrode, but because the coated tool provides concentrated spark energy during machining, more material was removed, as evident from the coated electrode edge. e coated electrode showed an elliptical section, but the uncoated tool showed a parabola section due to the secondary reaction as it was used for machining the D2 steel [25].…”

Section: Comparison Of the Coated Tool And Uncoated Toolsmentioning

confidence: 99%

See 2 more Smart Citations

Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Anbuchezhiyan

Saravanan

Pugazhenthi

et al. 2022

Advances in Materials Science and Engineering

View full text Add to dashboard Cite

Machinability investigation of new material is one of the mandatory investigations to complete the purpose of creation of it. Electrical discharge machining (EDM) is one of the promising unconventional machining processes for highly accurate machining performance in difficult-to-cut material even machining complicated profiles. The powder-mixed EDM and nanopowder-mixed EDM are the improved versions of the EDM. The Al–Zn–Mg composite is reinforced with Si3N4 (9 wt. %) for meeting automotive and marine applications. The aluminium nanoparticles enhanced deionised water was used in NPMEDM. The nickel-coated brass and uncoated brass tube electrode were considered for the investigation. Pulse on time (µs), voltage (V), input current (A), and capacitance (nF) were independent variables and varied at 3 levels. The microhole machining performance with a coated and uncoated electrode was investigated. The L18 orthogonal array involved in the experimental design, material removal rate, and electrode wear rate were analysed. The SEM analysis was employed in the surface morphological study of electrodes before and after machining. The input parameters were optimised for the coated electrode for the responses of MRR and EWR.

show abstract

“…From the SEM image, EWR is more on the bottom section of the brass tube. e effects have good agreement with the machining of D2 steel [25].…”

Section: Analysis Of the Edge Of The Toolsupporting

confidence: 58%

Section: Surface Analysis Of the Coated Toolmentioning

confidence: 71%

Section: Comparison Of the Coated Tool And Uncoated Toolsmentioning

confidence: 99%

See 1 more Smart Citation

Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Anbuchezhiyan

Saravanan

Pugazhenthi

et al. 2022

Advances in Materials Science and Engineering

View full text Add to dashboard Cite

show abstract

“…At higher current owing to the high intensity, it erodes high quantity of materials from the electrodes, results in increase in TWR. In case of Ton, a maximum of 1.79 mm 3 min −1 was recorded for 6 μs and it reduces to 1.12 mm 3 min −1 when the Ton was increased to 10 μs [34]. The results revealed that the most of the generated heat was transferred to the work piece.…”

Section: Influence Of Various Process Parameters On the Twr Of Incone...mentioning

confidence: 87%

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

KT,

et al. 2024

Mater. Res. Express

View full text Add to dashboard Cite

In this research, an attempt was made to reinforce aluminium with graphite particles and use it as a tool material with the objective of combining the properties of aluminium and graphite. The micrograph confirms that the graphite particles were uniformly distributed over the aluminium matrix, density reduces and thermal conductivity increases with the addition of graphite particles. Material Removal Rate (MRR) peaks at 12A current before declining due to plasma channel expansion, an optimal Ton of 8µs ws observed, with 4µs Toff yielding higher MRR. Copper electrodes excel due to thermal conductivity, while 5% graphite in aluminum boosts MRR to 31.89mm³/min, additional graphite decreases MRR. TWR rises with shorter Toff until 6µs, then decreases. Gap control impacts TWR, with lower spark gaps causing higher TWR due to intense material removal, and higher gaps leading to increased TWR due to incomplete flushing. Copper electrodes have the lowest TWR due to their high melting temperature. The addition of graphite in aluminum reduces TWR at low currents but is less effective at higher currents. Surface roughness (Ra) decreases with higher current, reaching a minimum of 7.02µm at 12A. Optimal Ton is 8µs (7.56µm), while shorter Toff at 4µs and a 3mm gap yield the best Ra of 7.36µm with A4 composite tool. Copper electrodes result in higher Ra at higher currents, while graphite in aluminum improves surface quality, especially at 5% content. Arcing, an undesirable electrical discharge phenomenon in EDM, adversely affects machining. Experiments revealed a strong correlation between high duty cycles, duty ratios, and arcing propensity, with composite tools being more susceptible due to their variable conductivity. In contrast, non-composite tools, exemplified by copper, withstand higher duty ratios without arcing.

show abstract

“…As the aspect ratio (AR) of the hole increases, debris accumulation is inevitable. To further improve the efficiency of deep-hole machining, some researchers proposed making use of coated tools [12–17]. Naveen et al [12], for instance, found that in Ti-6Al-4V alloy processing, silver coating is more favourable for material removal rate, while epoxy coating is beneficial for hole quality.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of the EDM tools coated with nano-alumina film

Gui

Gong

Sun

et al. 2023

Surface Engineering

View full text Add to dashboard Cite

During electrical discharge machining (EDM) drilling of small high-aspect-ratio holes, abnormal discharges between tool flank and workpiece will result in high process instability and poor shape accuracy. In order to solve this problem, dense nano-alumina insulating film is plated on the tool flank based on atomic layer deposition (ALD) to suppress the secondary discharge for the benefit of the tool's integrity and shape accuracy. Drilling experiments on nickel base superalloy GH4099 workpiece were conducted to test machining effect of the coated brass tool. Experimental results show that it can enhance the process stability and improve the surface topography of the machined holes. The tool wear is reduced by about 21.7%, and the discharge craters and carbon black film along the tool flank are significantly reduced.

show abstract

Influence of micro-electrical discharge machining parameters on the surface morphology of the nickel-coated electrode

Cited by 12 publications

References 31 publications

Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

Experimental investigation of the EDM tools coated with nano-alumina film

Contact Info

Product

Resources

About