Numerical modeling of electrical discharge machining of Ti-6Al-4V

Wu, Han; Ma, Jianfeng; Meng, Qingling; Jahan, Muhammad P.; Alavi, Farshid

doi:10.1016/j.promfg.2018.07.044

Cited by 18 publications

(8 citation statements)

References 43 publications

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“…Generally, the MRR increases with combined increase of peak current and pulse on time. The MRR was also increased with the increase of peak current, as with the increase of peak current the discharge energy per pulse increases resulting in larger crater (unit volume of material removed per pulse) [ 56 ].…”

Section: Resultsmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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Non-conductive structural ceramics are receiving ever-increasing attention due to their outstanding physical and mechanical properties and their critical applications in aerospace and biomedical industries. However, conventional mechanical machining seems infeasible for the machining of these superior ceramics due to their extreme brittleness and higher hardness. Electro discharge machining (EDM), well known for its machining of electrically conductive materials irrespective of materials hardness, has emerged as a potential machining technique due to its noncontact nature when complemented with an assistive electrode technique. This paper investigates the material removal mechanism and effects of machining parameters on machining speed and dimensional and profile accuracies of features machined on zirconia toughened alumina (ZTA) ceramics using assistive electrode EDM. Our experimental results demonstrate that both increasing peak current and pulse on time improves the MRR, however, it also aids in generating thicker layer on machined surface. In addition, pulse interval time is crucial for the machining of nonconductive ceramics, as larger value might cause the complete removal of intrinsic carbon layer which may lead to non/sparking condition. Higher peak current increases circularity whereas short pulse on and pulse off time aid in increasing circularity due to rough machining. In addition, taperness is found to be regulated by the peak current and pulse on time. Overall, thermal cracking and spalling appear to be a dominating material removal mechanism other than melting and evaporation for the EDM of ZTA.

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Section: Resultsmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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“…The first experiments for the validation of the thermal model using the properties and parameters described in Table 1 consisted of the analysis of single tracks. The temperatures obtained during the simulation of the process reached a maximum value of 3500 K ( Figure 5) which exceeds the melting (1659.85 °C) and boiling (2862 °C)temperature of Ti-6Al-4V [15]. From the cross-section of an experimental single track, it is possible to observe the depths of the melting and heat affected zones ( Figure 6).…”

Section: Melting and Heat Affected Zonementioning

confidence: 97%

Laser polishing of additively manufactured Ti-6Al-4V: Microstructure evolution and material properties

Solheid

Mohanty

Bayat

et al. 2020

Journal of Laser Applications

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Laser polishing of metals consists of irradiating the part's surface with a laser beam, thus generating a molten layer that is redistributed and resolidified to create a surface with reduced roughness. However, the process is also characterized by an instantaneously formation of heat-affected zones with consequent microstructural changes that influences the mechanical properties. In order to understand the microstructural evolution during laser polishing of Ti-6Al-4V laserbased powder bed fusion samples, a thermal model is applied in the current study to predict the dimensions of the melted zones and the heat-affected areas. Furthermore, the results obtained through the simulations are discussed and compared to the experimental data, thereby establishing the validity of the process models. Finally, the experimental studies also include the evaluation of the material hardness and residual stresses after laser polishing.

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“…The EDM process involves a wide range of phenomena, such as phase transitions [79][80][81], melt behavior [82][83][84], oxidation [36,50,85], residual stresses [86][87][88][89][90], energy transfer, absorption and dissipation [91][92][93][94], chemical reactions [75,95], microstructural changes [53,81,96], etc. The EDM process is generally based on the melting and evaporation of material under the influence of highly concentrated electrical energy, which is converted into thermal energy.…”

Section: Edm Process Physicsmentioning

confidence: 99%

“…In ceramic composites, depending on the strength of the discharge, it is possible to observe the breakage or fracture of reinforcing fibers and brittle fracture of the matrix [102]. The EDM process involves a wide range of phenomena, such as phase transitions [79][80][81], melt behavior [82][83][84], oxidation [36,50,85], residual stresses [86][87][88][89][90], energy transfer, absorption and dissipation [91][92][93][94], chemical reactions [75,95], microstructural changes [53,81,96], etc.…”

Section: Edm Process Physicsmentioning

confidence: 99%

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

Kamenskikh,

Muratov,

Shlykov

et al. 2023

JMMP

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Electrical discharge machining (EDM) is a highly precise technology that not only facilitates the machining of components into desired shapes but also enables the alteration of the physical and chemical properties of workpieces. The complexity of the process is due to a number of regulating factors such as the material of the workpiece and tools, dielectric medium, and other process parameters. Based on the material type, electrode shape, and process configuration, various shapes and degrees of accuracy can be generated. The study of erosion is based on research into processing techniques, which are the primary tools for using EDM. Empirical knowledge with subsequent optimization of technological parameters is one of the ways to obtain the required surface quality of the workpiece with defect minimization, as well as mathematical and numerical modeling of the EDM process. This article critically examines all key aspects of EDM, reflecting both the early foundations of electrical erosion and the current state of the industry, noting the current trends towards the transition of EDM to the 5.0 industry zone in terms of safety and minimizing the impact of the process on the environment.

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Numerical modeling of electrical discharge machining of Ti-6Al-4V

Cited by 18 publications

References 43 publications

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Laser polishing of additively manufactured Ti-6Al-4V: Microstructure evolution and material properties

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

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