Micro-electro discharge machining drilling of stainless steel with copper electrode: The influence of process parameters and electrode size

D’Urso, Gianluca Danilo; Maccarini, Giancarlo; Quarto, Mariangela; Ravasio, Chiara; Caldara, Michele

doi:10.1177/1687814016676425

Cited by 22 publications

(20 citation statements)

References 19 publications

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“…The parameters of electrical discharge (discharge voltage, discharge current, and time pulse) determine the value of discharge energy. These parameters directly affect the surface integrity and material removal rate (MRR) [7,8,9,10]. The processing condition, type of dielectric, and electrode and workpiece material also have a strong influence on the quality of parts after EDM [11,12,13,14].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Świercz¹,

Oniszczuk-Świercz²

2019

Materials

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Electrical discharge machining (EDM) is an advanced technology used to manufacture difficult-to-cut conductive materials. However, the surface layer properties after EDM require additional finishing operations in many cases. Therefore, new methods implemented in EDM are being developed to improve surface characteristics and the material removal rate. This paper presents new research about improving the surface integrity of 55NiCrMoV7 tool steel by using reduced graphene oxide (RGO) flakes in the dielectric. The main goal of the research was to investigate the influence of RGO flakes in the dielectric on electrical discharge propagation and heat dissipation in the gap. The investigation of the influence of discharge current I and pulse time ton during EDM with RGO flakes in the dielectric was carried out using response surface methodology. Furthermore, the surface texture properties and metallographic structure after EDM with RGO in the dielectric and conventional EDM were investigated and described. The obtained results indicate that using RGO flakes in the dielectric leads to a decreased surface roughness and recast layer thickness with an increased material removal rate (MRR). The presence of RGO flakes in the dielectric reduced the breakdown voltage and allowed several discharges to occur during one pulse. The dispersion of the discharge caused a decrease in the energy delivered to the workpiece. In terms of the finishing EDM parameters, there was a 460% reduction in roughness Ra with a uniform distribution of the recast layer on the surface, and a slight increase in MRR (12%) was obtained.

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Section: Introductionmentioning

confidence: 99%

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Świercz¹,

Oniszczuk-Świercz²

2019

Materials

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“…The electric discharge drilling (EDD) is generally used for drilling starting holes for wire-EDM applications and turbine blade cooling holes. A continuously rotating hollow metal electrode flushed by a dielectric fluid removes material by electric discharges [4][5][6].…”

Section: ӏ Introductionmentioning

confidence: 99%

Effect of Machining on Workpiece Surface Characteristics in Electric Discharge Drilling (EDD)

Erdem

Çoğun

Uslan

2019

International Journal of Advances in Engineering and Pure Sciences

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In electric discharge drilling (EDD), rapid local heating and cooling of the workpiece surface by means of electric discharges results in surface layers (recast, heat affected and base material). In this study, the main workpiece surface texture measures, namely the recast layer thickness (RLT) and average surface roughness (R a) characteristics were investigated for varying machining parameters (discharge current and pulse on time). The conducted experiments revealed the strong dependence of surface characteristics on machining parameters.

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“…The dielectric fluid present in the spark gap is responsible for the material removal mechanism through discharging phenomena. [38][39][40] The surface integrity and other quality features highly depend on the dielectric used. 41 The dielectric performs several essential functions, including insulation, ionization, removal of debris, and cooling the spark heat.…”

Section: Dielectric Fluids and Their Breakdown Mechanismmentioning

confidence: 99%

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

Chaudhary

Siddiquee

Chanda³

et al. 2014

Advances in Mechanical Engineering

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Generally, gear is an essential component in various electro-mechanical devices, but its manufacturing at the micro-level is challenging. The non-conventional manufacturing processes, such as electro-discharge machining (EDM), is suitable in gear fabrication. Although miniature gears have strict accuracy requirements, the optimization of the EDM process parameters, especially for advanced materials and alloys, is critical. In this paper, Nimonic alloy miniature gears are manufactured using wire-EDM and the effect of process parameters, such as peak current, pulse-off (POFF) time, pulse-on (PON) time, wire tension, and dielectric fluid on the response factors are analyzed. The primary response factors, such as surface roughness, machining time, material removal rate, kerf width (KW), surface microhardness, and depth of microhardness are considered. Also, different dielectric fluids are prepared, which include ethylene glycol mixed demineralized water, oxygen mixed demineralized water, ethylene glycol and alumina powder mixed demineralized water, and ethylene glycol alumina powder and oxygen mixed demineralized water. Furthermore, the effect of process parameters on the multi-response using Pareto ANOVA has been analyzed. The results demonstrate that ethylene glycol mixed demineralized water, as a dielectric fluid, is the most influencing parameter to reduce the surface roughness, machining time, KW, and improve micro-hardness. Thus, dielectric fluid is an essential factor obtained from multi-response optimization followed by peak current, POFF time, wire tension, and PON time.

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Micro-electro discharge machining drilling of stainless steel with copper electrode: The influence of process parameters and electrode size

Cited by 22 publications

References 19 publications

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Effect of Machining on Workpiece Surface Characteristics in Electric Discharge Drilling (EDD)

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

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