Study on effect of tool motion strategies on tool wear characteristics during generation of non-circular cavities by electro discharge machining process

Mathai, Vishal John; Dave, Harshit K.; Desai, Keyur P.

doi:10.1504/ijmmm.2015.070921

Cited by 4 publications

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“…The authors have attempted two different strategies viz. diagonal and planetary for generation of square shaped cavities in the prior research on tool actuation and observed that planetary performs better than diagonal in terms of material removal rate and tool distortion [2,32]. Hence the present study has been carried out using planetary tool actuation.…”

Section: Experimental Plan and Procedures 21 Tool Actuation Strategymentioning

confidence: 97%

Experimental investigations on EDM of Ti6Al4V with planetary tool actuation

Mathai

Dave

Desai

2016

J Braz. Soc. Mech. Sci. Eng.

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Section: Experimental Plan and Procedures 21 Tool Actuation Strategymentioning

confidence: 97%

Experimental investigations on EDM of Ti6Al4V with planetary tool actuation

Mathai

Dave

Desai

2016

J Braz. Soc. Mech. Sci. Eng.

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“…Side injection flushing with 0.25 kg/cm 2 pressure has been used for flushing during the process. For tool actuation, helical tool path strategy has been employed as the same is reported to have good effectiveness for generation of square shaped features than other planetary strategies like diagonal [19]- [20]. In helical tool path strategy, the tool is actuated along a path parallel to the final outline of the cavity, at a distance equal to tool path offset from the axis of the final cavity (Fig.…”

Section: Study On Effect Of Process Parameters On End Wear Of Tool Elmentioning

confidence: 99%

Study on Effect of Process Parameters on End Wear of Tool Electrode during Planetary EDM of Ti-6Al-4V

Mathai¹,

Dave²,

Desai³

2017

IJMMM

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Abstract-Electro Discharge Machining (EDM) is one of the most widely accepted advanced machining process to machine hard to machine electrically conductive materials. However, the inferior physical properties of the workpiece tend to make process unstable resulting into heavy loss of material from the tool electrode thereby leading in to generation of inaccurate features. In present work, an attempt has been made to study the effect of various process parameters viz. pulse ON time, duty factor, gap voltage and polarity of the tool electrode on end wear of the tool electrode and wear ratio during planetary EDM of Ti-6Al-4V. One factor at a time methodology has been employed to study the parameter effects. Results suggest that distortion on the tool electrode during EDM of Ti-6Al-4V is highly influenced by the pulse ON time level as well as polarity of the tool electrode employed. Further, it has also been understood that lower levels of duty factor and higher levels of gap voltage are preferable for efficient machining of titanium alloys.Index Terms-EDM, planetary, titanium, tool kinematics, wear. I. INTRODUCTIONTitanium and its alloys have wide range of application in various sectors like aerospace, biomedical, chemical processing plants etc. owing to its high strength to weight ratio, excellent biocompatibility and good corrosion resistance. But the inferior property values for thermal conductivity, elastic modulus, volume specific heat etc. make it a material difficult to machine [1], [2]. Therefore advanced machining techniques like Electro Discharge Machining (EDM) process is commonly used for processing such materials. The process removes material with the aid of repetitive and controlled electrical sparks in the presence of a dielectric medium, which results into localized rise in temperature on both tool electrode and workpiece surface, leading to melting and vaporization of the same [3]. The debris formed is immediately flushed out from the machining zone by the dielectric fluid.Even though the process can be applied for machining titanium based alloys, one of the issues that have been reported is the relatively higher intensity of wear of the tool electrode during machining. As EDM is a process in which the negative image of the tool electrode is generated on the Concept of cryogenic cooling of the tool electrode has also been studied by researchers and reported to have positive effect on process characteristics [9]. Out of these process improvement techniques, orbiting of the tool electrode have multi-facetted advantages as it improves flushing at the inter electrode gap, reduces tool wear and improves surface finish of the final feature. Further, the tooling cost can also be reduced significantly as a bigger cavity can be made using a smaller electrode [10].Different modes of planetary tool actuation strategies have been studied by researchers in EDM process carried out at micro as well as macro level. El-Taweel and Hewidy [11] studied the effectiveness of tool actuation strategies viz., spiral and he...

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“…Джафферсон (Jafferson) и Харихаран (Hariharan) [30] определили электросопротивление, размер кристаллитов, микротвердость и провели микроскопические исследования, а также сравнили параметры обработки криогенно обработанных и необработанных микроэлектродов при микроэлектроэрозионной обработке (МЭЭО). Влияние криогенно обработанных электродовинструментов на процессы электроэрозионной обработки (EDM) изучали Матай с соавторами (Mathai et al) [31]. Когда обработка выполняется с использованием электродов, подвергнутых криогенной обработке различной продолжительности, эффективность процесса оценивается путем изучения изменения критических характеристик отклика, таких как ССМ, ИИИ и шероховатость поверхности, в зависимости от тока и времени включения импульса.…”

Section: Introductionunclassified

Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys

Sawant,

Bulakh,

Jatti

et al. 2024

Metal Working and Material Science

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Introduction. In modern manufacturing world, industries should adapt technological advancements for precision machining of difficult-to-machine metals, especially for beryllium copper (BeCu) alloys. The electrical discharge machining of alloys has proven its viability. The purpose of the work. A literature review indicated that the investigation of electrical discharge machining of BeCu alloys is still in its infancy. Furthermore, the cryogenic treatment of workpieces and electrodes in electrical discharge machining has not received much attention from researchers. Moreover, the impact of magnetic field strength on surface integrity and productivity during electrical discharge machining has not attracted much attention from researchers. The methods of investigation. This paper describes the use of electrolytic copper with different gap current values, pulse on periods, and external magnetic strength for electrical discharge machining of BeCu alloys. This paper examines how the material removal rate, the thickness of the white layer, and the formation of surface cracks are affected by cryogenic treatment of the workpiece and tool, pulse-on time, gap current, and magnetic strength. Results and Discussion. The combination of the cryogenically treated BeCu workpiece and the untreated Cu electrode had the highest material removal rate among all the combinations of workpieces and tools used in this study. The pulse on-time and the strength of the magnetic field had little influence on material removal rate, whereas the gap current had the greatest effect. The maximum achieved material removal rate was 11.807 mm3/min. At a high material removal rate, the observed thickness of the white layer on the horizontal surface ranged from 12.92 µm to 14.24 µm. In the same way, the maximum and minimum values for the vertical surface were determined to be 15.58 µm and 11.67 µm, respectively. According to scanning electron microscopy, the layer thickness was less than 20 µm, and barely noticeable surface cracks were observed in specimens with low, medium and high material removal rates. Obviously, due to the cryogenic processing of the workpiece and the external magnetic strength, there was a slight cracking of the surface and the formation of a white layer.

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Study on effect of tool motion strategies on tool wear characteristics during generation of non-circular cavities by electro discharge machining process

Cited by 4 publications

References 0 publications

Experimental investigations on EDM of Ti6Al4V with planetary tool actuation

Experimental investigations on EDM of Ti6Al4V with planetary tool actuation

Study on Effect of Process Parameters on End Wear of Tool Electrode during Planetary EDM of Ti-6Al-4V

Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys

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