Influence of Wear Pattern of Graphite Electrode on EDM Geometric Accuracy of Slot Machining

Jia, Yuchao; Chi, Guanxin; Li, Wentong; Wang, Zhenlong

doi:10.1016/j.procir.2020.02.265

Cited by 6 publications

(2 citation statements)

References 16 publications

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“…For straight slots, conventional CNC machining is perfectly adequate, but it can be carried out using different strategies, although the surface roughness is a challenge to consider [2,3]. In fact, for the geometries of some complex parts applied in turbomachinery, electrical discharge machining can be more advantageous than chip-removing machining due to such complexity, the inherent difficulty of implementation, and the risk of obtaining surfaces with high roughness [4,5].…”

Section: Introductionmentioning

confidence: 99%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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Strategies for obtaining deep slots in soft materials can vary significantly. Conventionally, the tool travels along the slot, removing material mainly with the side cutting edges. However, a “plunge milling” strategy is also possible, performing the cut vertically, taking advantage of the tip cutting edges that almost reach the center of the tool. Although both strategies are already commonly used, there is a clear gap in the literature in studies that compare tool wear, surface roughness, and productivity in each case. This paper describes an experimental study comparing the milling of deep slots in AA7050-T7451 aluminum alloy, coated with a novel DLCSiO500W3.5O2 layer to minimize the aluminum adhesion to the tool, using conventional and plunge milling strategies. The main novelty of this paper is to present a broad study regarding different factors involved in machining operations and comparing two distinct strategies using a novel tool coating in the milling of aeronautical aluminum alloy. Tool wear is correlated with the vibrations of the tools in each situation, the cycle time is compared between the cases studied, and the surface roughness of the machined surfaces is analyzed. This study concludes that the cycle time of plunge milling can be about 20% less than that of conventional milling procedures, favoring economic sustainability and modifying the wear observed on the tools. Plunge milling can increase productivity, does not increase tool tip wear, and avoids damaging the side edges of the tool, which can eventually be used for final finishing operations. Therefore, it can be said that the plunge milling strategy improves economic and environmental sustainability as it uses all the cutting edges of the tools in a more balanced way, with less global wear.

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Section: Introductionmentioning

confidence: 99%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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“…The procedure entails the placement of electrodes on both sides of the materials to be joined, followed by firmly pressing these metal sheets together [12,13]. As the electrodes pass a high electrical current, the material's inherent resistance generates heat at the contact points [14,15]. The produced heat is sufficiently intense to melt the metal at these specific contact areas.…”

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confidence: 99%

The Box-Behnken Response Surface Methodology Approach to Optimize Tensile Strength Load in Resistance Spot Welding Using SPCC-SD Steel

Mulyadi,

Amir,

Cepi Budiansyah

et al. 2024

JTMMX

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This article describes an experimental investigation into optimizing spot welding resistance (RSW) using a spot-welding machine equipped with a dual-electrode Pressure Force System (PFS). The optimization procedure entails the incorporation of SPCC-SD (JIS G 3141), a low-carbon steel that finds extensive application in the automotive sector. With the widespread use of SPCC-SD steel, RSW is an essential process in the automotive industry for assembling body components. This study employs the Box-Behnken Response Surface Methodology (Box-Behnken-RSM) to optimize the tensile strength load (TS-load), a critical parameter in RSW, through a meticulous analysis of the interplay between Holding Time, Squeezing Time, Welding Current, and Welding Time. Through the methodical design of experiments, the collection of Tensile Strength Load data, and the application of statistical modeling via RSM, this study employs SPCC-SD steel to determine the optimal values for these variables in RSW. The results above readily offer a valuable understanding of the most significant determinants and their interrelationships, thus facilitating advancements in welding methodologies and quality control in the automotive manufacturing sector. This study employs the Box-Behnken Response Surface Methodology to investigate the impacts and interrelationships of different parameters thoroughly. It aims to enhance the TS-load using SPCC-SD steel during the resistance spot welding procedure. This research contributes to advancing welding methodologies employed in the automotive manufacturing sector.

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Determination of the Optimum Conditions for Machining NiTi Shape Memory Alloys by Electrical Discharge Machining

Güven,

Yilmaz,

Gökkaya

et al. 2024

J. Inst. Eng. India Ser. C

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Influence of Wear Pattern of Graphite Electrode on EDM Geometric Accuracy of Slot Machining

Cited by 6 publications

References 16 publications

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

The Box-Behnken Response Surface Methodology Approach to Optimize Tensile Strength Load in Resistance Spot Welding Using SPCC-SD Steel

Determination of the Optimum Conditions for Machining NiTi Shape Memory Alloys by Electrical Discharge Machining

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