Modeling Electrical Discharge Machining of Deep Micro-Holes by Rotating Tool-Electrode

Nguyen, Duc Chien; Волгин, В. М.; Lyubimov, V.V.

doi:10.1007/978-3-030-54817-9_20

Cited by 2 publications

(5 citation statements)

References 22 publications

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“…The vibrating base plate (5), due to its rigid connection with the vacuum Previously, using one of the known 3D-printing methods, a thin-walled shell mold (10) of the product is manufactured with projections (11) and the sprue (12) provided in it. The mold (10) is fixed in a clamp (9) inside the vacuum chamber (8) and, using a line (20), its sprue (12) is hermetically connected to the fitting (17), externally, using the line (20) and taps (18) connected to the container (21), which contains a liquid metal-polymer composition. The container ( 21) can be either a simple volume vessel or one of the known devices for mixing and dosing two-component compounds, such as metal polymers.…”

Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

“…The vacuum pump (4) is turned on, which, through a vacuum line (19) connected to a valve (18), which in turn is connected through a fitting (17) to the vacuum chamber (8), pumps out air from the vacuum chamber (8), creating a vacuum in it of up to 400 Pa (to the level of boiling of the metal polymer). In this case, the cover (13), due to the seal ( 14), is tightly pressed against the open end of the vacuum chamber (8).…”

Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

“…After the appearance of the liquid metal polymer in the vents (11), by closing the valves (18) on the vacuum chamber (8) and the container (21), through which the liquid metal polymer is supplied, the supply of the liquid metal polymer to the mold is stopped, and the vibrators ( 22) are turned off. The line (20) connecting the container (21) with the vacuum chamber ( 8) is disconnected from the tap (18).…”

Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

“…For example, electrical discharge machining technologies require, in addition to an electrical discharge machine, the production of an electrode tool. Also, when piercing spiral holes, it is necessary to combine the translational and rotational motion of the workpiece and the electrode tool [17][18][19][20][21][22]. These and other technological limitations force many enterprises to abandon the development of complex production technologies and limit themselves to the production of simpler designs.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

Lubimyi,

Chepchurov,

Polshin

et al. 2024

JMMP

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This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation and justification of the selected loads on the drill body arising from metal-cutting forces. The described methodology for designing a digital model of a metal-cutting tool for the purpose of its further production using SLM 3D metal printing methods facilitates the procurement of a digital model characterized by a reduced weight and volume of material. The described design technology involves the production of a thin-walled outer shell that forms the external technological surfaces necessary for the drill body, as well as internal structural elements formed as a result of topological optimization of the product shape. Much attention in this article is paid to the description of the technology for filling internal cavities with a viscous metal polymer, formed as a result of the topological optimization of the original model. Due to this design approach, it is possible to reduce the volume of 3D metal printing by 32%, which amounts to more than USD 135 in value terms.

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Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

Section: Filling Internal Cavities With Metal Polymermentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

Lubimyi,

Chepchurov,

Polshin

et al. 2024

JMMP

View full text Add to dashboard Cite

show abstract

“…Beyond internal geometries, other authors investigated external geometric modifications of tool electrodes in ED drilling, like D-shaped or elliptic tool electrodes [23,24], rotating graphite tool electrodes with eight different cross sections [25], a stirrer-shaped tool electrode [26], internal or external inclined pathways through rod tool electrodes [27][28][29], eccentric micro-slots in tool electrode tips [30], a rectangular tool electrode cross-section [31], or radially arranged straight and helical slots [7,[32][33][34][35]. YADAV ET AL., NASTASI AND KOSHY, and NATSU ET AL.…”

Section: State Of the Artmentioning

confidence: 99%

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

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The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.

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Modeling Electrical Discharge Machining of Deep Micro-Holes by Rotating Tool-Electrode

Cited by 2 publications

References 22 publications

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

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