Modeling Debris Motion in Vibration Assisted Reverse Micro Electrical Discharge Machining Process (R-MEDM)

Mastud, Sachin; Kothari, Naman S.; Singh, Ramesh; Joshi, Suhas S.

doi:10.1109/jmems.2014.2343227

Cited by 47 publications

(22 citation statements)

References 23 publications

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“…However, the precise real-time observation of the generation and movement of EDM debris through experiments is difficult. So, analytical and computational modeling have been explored [10,20,116,22,23]. However, these models did not account for the impact force associated with the plasma discharge, which is one of the critical factors affecting the dielectric flow and trajectory of debris particles.…”

Section: Debris Flushing 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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Section: Debris Flushing Modelmentioning

confidence: 99%

“…al. [23] recently developed a 2-dimensional, axisymmetric model to study debris motion during the reverse micro-electrical discharge machining process. However, this model did not account for plasma explosion pressure.…”

Section: Debris Flushing Modelmentioning

confidence: 99%

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

Pattabhiraman

Marla

Kapoor

2015

Volume 1: Processing

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“…Mastud et al set up a simulation model of debris movement with ultrasonic vibration. The study found that the amplitude and frequency make the effect of debris movement and accelerate the debris movement [ 8 ]. Chang et al studied the pressure field, velocity field, and the concentration of debris in machining gap during a period of ultrasonic vibration with Fluent.…”

Section: Introductionmentioning

confidence: 99%

A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes †

Chang

Zhang

et al. 2018

Micromachines

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When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software, Fluent, a three-dimensional (3D) model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. The laws of different amplitudes and frequencies and different aspect ratios on debris distribution and movement are quantitatively analyzed. The motion height of debris was observed under different conditions. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. When compared to traditional small hole machining in EDM, the debris in the machining gap were greatly reduced, which ensures the stability of the machining process and improves the machining efficiency.

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“…Kim et al fabricated various shapes of micro tools by R-µEDM and investigated the effects of capacitance and voltage on machining time [3]. Vibration-assisted R-µEDM process for the fabrication of micro-rod has been used and it has been reported that the use of plate electrode with lower thickness leads to an improvement of erosion rate and surface roughness [6]. The Vibration-assisted R-µEDM process is also shown to help in dispelling the debris particles from the inter-electrode gap and this has been illustrated using the simulation model for modelling of debris motion with dielectric flow [7].…”

Section: Introductionmentioning

confidence: 99%

“…The Vibration-assisted R-µEDM process is also shown to help in dispelling the debris particles from the inter-electrode gap and this has been illustrated using the simulation model for modelling of debris motion with dielectric flow [7]. Taguchi based design of experiment has been used to study the effect of process parameters on response measures [6,[8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Experimental Analysis of Reverse Micro-EDM for Machining Microtool

Singh

Patowari

Deshpande

2015

Materials and Manufacturing Processes

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High aspect ratio micro tools find numerous applications in the production of miniaturized components and structures for example, drilling of micro holes in ink jet nozzles, air bearings and biomedical devices, etc. The present study aims to machine micro rods using Reverse Micro Electrical Discharge Machining (R-µEDM) process.These micro rods can be used as micro tools for drilling micro holes. A detailed experimental investigation has been carried out with the help of Taguchi's orthogonal array for understanding the mechanism of the process. The process parameters such as voltage, feed rate and capacitance are considered to perceive their effect on response measures such as machining time, deviation in length, deviation in average diameter, standard deviation (SD) in diameter and surface roughness. The optimal process parametric condition of R-µEDM has been determined for desired performance i.e., obtaining the target length and average diameter of the micro rod and ensuring its straightness with minimum time duration. Confirmation experiment has been carried out at the optimum condition and accordingly the results have been presented. Surface morphology of the machined micro rod at the optimum condition has also been Downloaded by [University of Otago] at 21:36 27 July 2015 2 investigated. Micro rod of diameter 170 µm with a high aspect ratio of 18 has been successfully machined using this process.

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Modeling Debris Motion in Vibration Assisted Reverse Micro Electrical Discharge Machining Process (R-MEDM)

Cited by 47 publications

References 23 publications

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

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

A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes †

Experimental Analysis of Reverse Micro-EDM for Machining Microtool

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