Microanalysis of debris formed during rotary EDM of titanium alloy (Ti 6A1 4V) and die steel (T 215 Cr12)

Soni, J.S.

doi:10.1016/0043-1648(94)90119-8

Cited by 72 publications

(38 citation statements)

References 8 publications

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“…The high pressure generated by this inertia enclosure effect rapidly removes molten metals from the surface of machined materials. Studies on EDM characteristics primarily considers tool-steel alloys; experimental data related to the EDM characteristics of conductive ceramic and Ti alloys, [5][6][7][8][9] and the effects of compound phases on the EDM characteristics of Al alloys in terms of SiC/Al compound materials. 10) Furthermore, Ramulu and Taya stated that the MRR of silicon carbide whiskers (SiCw) compound materials varied according to the volume fraction of second-phase SiCw.…”

Section: Introductionmentioning

confidence: 99%

Effect of Silicon Particles on the EDM Characteristics of Al-Si Alloys

Tsai¹,

Lui²,

Chen³

2002

Mater. Trans.

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The second phase of the Aluminum-Silicon (Al-Si) alloy embedded in microstructure includes primary silicon particles and hypereutectic silicon particles. Variations in the area fraction of these silicon particles significantly influences Electro Discharge Machining (EDM) characteristics. The area fraction of these silicon particles is proportional to materials removal rate (MRR). Experimental data obtained using Scanning electron microscope (SEM) revealed that discharge craters were formed as a ridge on the EDMed surface. The increased average surface roughness (Ra) resulted in an increased EDM rate. The area fraction of second phase silicon particles, and the ridge density on the rapidly resolidified layer of the EDMed surface tended to increase. However, most silicon particles were found on the peaks on the sub-layer of the EDMed surface, formed by rapidly solidification of molten fluid during discharge melting. Therefore the presence of silicon particles in the rapidly resolidified layer was largely governed by the formation of discharge peaks. The formation of peaks was governed by EDM conditions and silicon content. The electrodes showed stable wear during EDM when the pulse duration exceeded 150 µs. Wear increased as the area fraction of silicon particles increased.

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Section: Introductionmentioning

confidence: 99%

Effect of Silicon Particles on the EDM Characteristics of Al-Si Alloys

Tsai¹,

Lui²,

Chen³

2002

Mater. Trans.

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“…The plunging movement of the tool electrode during discharges has been stud- A similar approach of rotating the tool electrode instead of the workpiece was developed by researchers [80,81,12,82]. Soni and Chakraverti (1994) [12] observed that material removal was higher with rotation of the tool electrode due to improved flushing action and sparking efficiency.…”

Section: Tool Movementmentioning

confidence: 99%

“…Soni and Chakraverti (1994) [12] observed that material removal was higher with rotation of the tool electrode due to improved flushing action and sparking efficiency. This technique can be used to machine axially non-symmetric features too.…”

Section: Tool Movementmentioning

confidence: 99%

“…3.9 and Eqn. 3.10 and are defined as, m s =ṁ d and (3.11) 12) where,ṁ d is flow rate of the droplet stream impinging on the wall and V d , V f are the velocities of the droplet stream and liquid film, respectively. A first-order explicit scheme is used for both spatial and temporal discretization of film parameters.…”

Section: Model Description Eulerian Wall Film (Ewf) Modelmentioning

confidence: 99%

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Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Pattabhiraman

Marla

Kapoor

2015

Volume 1: Processing

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Electrical Discharge Machining is a non-traditional machining process that is widely used in the tool and die-making industry, automotive, and aerospace industries due to its ability to produce complex three-dimensional geometries with good accuracy and surface finish. Despite the aforementioned advantages, the consumption of a large quantity of dielectric (especially hydrocarbon oils) poses a significant health and environmental hazard including respiratory and skin irritation issues. Further, the disposal of waste dielectric that contains a significant amount of metal particulates poses safety concerns. In order to comply with environmental safety standards, extensive filtration and treatment systems capable of handling huge amounts of dielectric waste need to be set up for their safe disposal.This leads to an increased energy consumption and hence higher operating cost for the machining process. Thus, there is a need to reduce the consumption of oil-based dielectrics without compromising their superior machining performance.Several techniques including dry and near-dry EDM have been developed to reduce the consumption of dielectrics. However, they have poor debris flushing capability. This research seeks to develop a technique that minimizes the consumption of dielectrics and also improves the flushing of debris from the inter-electrode gap.A novel method of using atomized dielectric spray in EDM (Spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the inter-electrode gap and acts as a single-phase dielectric medium between the electrodes. It also effectively removes the debris particles from the discharge zone. Single-discharge EDM experiments are performed using ii three different dielectric supply methods, viz., conventional Wet-EDM (electrodes submerged in dielectric medium), Dry-EDM and Spray-EDM in order to compare the processes based on material removal, tool electrode wear and flushing of debris from the inter-electrode gap across a range of discharge energies. It is observed that Spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study.The tool electrode wear using atomized dielectric is significantly better than Dry-EDM and comparable to that observed in Wet-EDM. The percentage of debris particles deposited within a distance of 100 µm from the center of EDM crater is also significantly reduced using the Spray-EDM technique. iv

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“…However, Soni related the formation of debris during rotary electrical discharge machining of titanium alloy and high carbon high chromium die steel. 9) Many distinct types of spheroidal particles were witnessed and the mechanisms of their formation were discussed. Willey related hollow, dented and cracked particles with solidification from the vapor phase in the dielectric fluid.…”

Section: Introductionmentioning

confidence: 99%

Fabrication Method for a TiO<SUB>2</SUB> Nanofluid with High Roundness and Superior Dispersion Properties

Chang

Lin

2007

Mater. Trans.

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This study describes the use of a new submerged arc nanofluid synthesis system to fabricate TiO 2 nanofluids. Under vacuum conditions, this system uses the energy produced by an arc discharge to vaporize the desired metal. Then, the vaporized metal is cooled rapidly in a lowtemperature dielectric liquid, forming nanoparticles that are evenly distributed inside the dielectic liquid. Experiments show that the fabricated TiO 2 nanoparticles are much better than those fabricated by aerosol methods. In addition, the fabricated nanofluid has high suspension stability. We use X-ray diffraction to analyze the structure of TiO 2 nanofluid. By measuring the Zeta potential of the TiO 2 nanofluid with different pH values, the suspension stability of the TiO 2 nanofluid is demonstrated. To verify the applicability of the TiO 2 nanofluid, this study also analyzes and compares the rheological properties and reaction to light absorption of nanofluids with different average particle sizes.

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Microanalysis of debris formed during rotary EDM of titanium alloy (Ti 6A1 4V) and die steel (T 215 Cr12)

Cited by 72 publications

References 8 publications

Effect of Silicon Particles on the EDM Characteristics of Al-Si Alloys

Effect of Silicon Particles on the EDM Characteristics of Al-Si Alloys

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Fabrication Method for a TiO<SUB>2</SUB> Nanofluid with High Roundness and Superior Dispersion Properties

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