Multiphysics modelling and high-speed imaging-based validation of discharge plasma in micro-EDM

Kishore, Hreetabh; Nirala, Chandrakant K.; Rajurkar, K. P.

doi:10.1016/j.cirpj.2023.02.006

Cited by 15 publications

(4 citation statements)

References 36 publications

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“…The increase in pulse ON time from 50 µs to 75 µs resulted in a rougher surface with the highest Ra, 5.5 µm, as shown in Figure 6 b, because of the discharge energy transfer and accumulation of heat energy for a longer time period. However, a further increase in pulse ON time resulted in a slight decrease in roughness to ~5.3 µm because of the promotion of an arcing phenomenon during the spark generation against the long pulse duration [ 28 ]. During arcing, the discharge column significantly expands because of a longer pulse duration.…”

Section: Resultsmentioning

confidence: 99%

“…For this reason, four electrodes, including copper (Cu), brass (Br), graphite (Gr), and aluminum (Al) electrodes, were used to machine the workpiece, each having a 15 mm diameter. Similarly, Raza et al [ 28 ] discussed the influence of material properties on processing conditions, motivating the choice of four electrode materials. The physical properties of tool electrodes which influence the process are mentioned in Table 2 .…”

Section: Methodsmentioning

confidence: 99%

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Electric Discharge Machining of Ti6Al4V ELI in Biomedical Industry: Parametric Analysis of Surface Functionalization and Tribological Characterization

et al. 2023

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The superior engineering properties and excellent biocompatibility of titanium alloy (Ti6Al4V) stimulate applications in biomedical industries. Electric discharge machining, a widely used process in advanced applications, is an attractive option that simultaneously offers machining and surface modification. In this study, a comprehensive list of roughening levels of process variables such as pulse current, pulse ON time, pulse OFF time, and polarity, along with four tool electrodes of graphite, copper, brass, and aluminum are evaluated (against two experimentation phases) using a SiC powder-mixed dielectric. The process is modeled using the adaptive neural fuzzy inference system (ANFIS) to produce surfaces with relatively low roughness. A thorough parametric, microscopical, and tribological analysis campaign is established to explore the physical science of the process. For the case of the surface generated through aluminum, a minimum friction force of ~25 N is observed compared with the other surfaces. The analysis of variance shows that the electrode material (32.65%) is found to be significant for the material removal rate, and the pulse ON time (32.15%) is found to be significant for arithmetic roughness. The increase in pulse current to 14 A shows that the roughness increased to ~4.6 µm with a 33% rise using the aluminum electrode. The increase in pulse ON time from 50 µs to 125 µs using the graphite tool resulted in a rise in roughness from ~4.5 µm to ~5.3 µm, showing a 17% rise.

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Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Electric Discharge Machining of Ti6Al4V ELI in Biomedical Industry: Parametric Analysis of Surface Functionalization and Tribological Characterization

et al. 2023

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“…This technique influences chip formation and reduces tool wear, potentially revolutionizing manufacturing processes. Raza et al [ 113 ] used multiphysics modelling and high-speed imaging validation to study discharge plasma phenomena in μEDM. It uses computational simulations to understand interactions and validate findings with high-speed imaging experiments.…”

Section: Some Other Monitoring and Compensation Methodsmentioning

confidence: 99%

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

Nadda,

Nirala,

Singh

et al. 2024

Heliyon

Self Cite

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“…To this aim, the 2D frequency domain model was implemented in the plasma module of COMSOL Multiphysics. Following the path reported by the previous literature [22][23][24][25][26], the study was carried out by coupling the electromagnetic and heat transfer apparatus to the fluid modules. Differently from the literature, the permittivity of deionized and tap water was also included in the model.…”

Section: Micro-edm Simulation: Plasma Channel Distribution and Remove...mentioning

confidence: 99%

How the Electrical Conductivity of Water Fluids Affects Micro-EDM in the Short-Pulse Regime

Marrocco,

Modica,

Bellantone

et al. 2024

Micromachines

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This work investigates micro-electro discharge machining (EDM) performance involving deionized and tap water. The chosen machining regime was semi-finishing, where open voltage (from 100 to 130 V) and current values (5–10 A) were applied using a 0.5 µs pulse-on time and a frequency of 150 kHz, i.e., a duty cycle of 25%. First, numerical analyses were performed via COMSOL Multiphysics was used to estimate the plasma channel distribution and melted material, varying the current, sparking gap, electrical conductivity, and permittivity of the two fluids. Then, experimentally, the micro-EDM of holes and channels in hardened thin steel plates were replicated three times for each considered fluid. The material removal rate (MRR), tool wear ratio (TWR), radius overcut, and surface roughness were plotted as a function of open voltage and electrical conductivity. The study proves that as voltage and current increase, the MRR and TWR decrease with electrical conductivity. Nonetheless, for higher electrical conductivity (tap water), the process did not proceed for lower open voltages and currents, and the radius overcut was reduced, contrary to what is commonly acknowledged. Finally, the crater morphology and size were evaluated using a confocal microscope and compared to simulated outcomes.

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Multiphysics modelling and high-speed imaging-based validation of discharge plasma in micro-EDM

Cited by 15 publications

References 36 publications

Electric Discharge Machining of Ti6Al4V ELI in Biomedical Industry: Parametric Analysis of Surface Functionalization and Tribological Characterization

Electric Discharge Machining of Ti6Al4V ELI in Biomedical Industry: Parametric Analysis of Surface Functionalization and Tribological Characterization

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

How the Electrical Conductivity of Water Fluids Affects Micro-EDM in the Short-Pulse Regime

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