Surface modification during electrical discharge machining process – A review

Kumar, Sudhanshu; Verma, Abhishek

doi:10.1016/j.matpr.2020.08.596

Cited by 9 publications

(5 citation statements)

References 31 publications

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“…Furthermore, the experimental results showed that the thickness of recast layer increased with the increase of peak current, which had the same trend as the in uence of peak current on surface roughness. Other studies showed that the thickness of metamorphic layer in surface increased with the increase of roughness of machined surface [19,20], it can be concluded that reducing the surface roughness of EDM can also reduce the thickness of machined metamorphic layer.…”

Section: Optimal Analysis For Anging Width Of Holementioning

confidence: 86%

Investigation on Orbital EDM for Double-Hole Thin Wall of Integrated Flexible Joint

Liu

et al. 2021

Preprint

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The thin neck structure of integrated flexible joint is the key factor to realize high-precision navigation in dynamically tuned gyroscope. The thin neck structure is composed of two adjacent circular holes and the thin wall between the two holes. The thin wall is easy to deform under the external force and vibration exerted by the tool when using traditional machining methods such as drilling and boring, and the cutting tools are easily to be damaged for the machining of small holes in superhard materials, inducing high processing cost. Aiming at these problems, the machining method of double-hole thin wall in the step-by-step orbital electrical discharge machining (EDM) with a high rotation speed electrode is proposed. The procedure for EDM of double-hole flexible thin wall is designed, and the process parameters of each step machining are optimized using orthogonal experiment and signal-to-noise ratio analysis. The machining experiments of double-hole thin wall of 3J33B material are proceed using the optimized parameters. The results show that the hole diameter of the double-hole flexible thin wall is 2 mm, the hole depth is 8mm, and the average thickness of the thin wall is about 46.5 μm. The thickness range between the measured point and the average is 1.55 μm, that compared with average thickness of 46.5 μm, the error is less than 3%, the overall thickness is uniform relatively.

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Section: Optimal Analysis For Anging Width Of Holementioning

confidence: 86%

Investigation on Orbital EDM for Double-Hole Thin Wall of Integrated Flexible Joint

Liu

et al. 2021

Preprint

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“…These techniques provide with tools to fine tune material surfaces for longer operations and improved performance. Some of the well-known surface modification techniques and their respective applications are as follow: 1) Laser Surface Modification: Laser based methods such as laser hardening and laser alloying are used to heat the surface and alter the surface properties of the materials [4]. The laser based techniques have high precision and control in enhancing surface hardness and wear resistance which makes them the ideal techniques for application in automotive industries where increased gear and shaft durability is needed [32].…”

Section: IImentioning

confidence: 99%

“…Understanding these following mechanisms is crucial for optimizing the EDM process [4]: 1) Erosion of Electrode Material: One of the fundamental processes in EDM is the erosion of the electrode material [5]. When electric discharge occurs between the tool electrode and the workpiece an intense heat is generated which causes the tool material to vaporize and erode [6].…”

Section: Mechanism Of Surface Modification Surface Modification Throu...mentioning

confidence: 99%

Surface Modification using Composite Electrodes in EDM: A Review

Thakur,

Pabla

2023

IJRASET

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EDM has been widely used for material removal purposes for manufacturing complicated shapes in the hard to machine materials and has been used commercially for making cutting tools and dies. An extended use of EDM for surface modification through coating has also been reported in research studies. Researches have reported that surface modification and coating using EDM has resulted in significant advancements in surface quality, hardness and corrosion resistance in addition to the saving in the cost of the tooling materials as desired properties at the surface that have been produced using low cost materials for making base tool and providing surface coating to get the desired surface characteristics. Researches have reported that the composite electrodes have variable effects on the surface modification using EDM depending upon factors like the material used and the manufacturing process for making of composite tool. Most composite electrodes are made by mixing materials during molten state and such but in this study the electrode is made by fitting one material inside other. Researchers have adopted different methods of surface modification using metal coating including EDM. A review of literature for surface modification using EDM is presented in this paper. In addition, studies have been conducted on the use of composite electrodes and their varying effects on both EDM machining and EDM based surface modification.

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“…The machined surface can be modified in different ways, including conventional electrode materials, powder metallurgy (P/M) electrodes, and powder suspended in dielectric fluid [7]. Powder Metallurgy electrodes are technologically feasible for the EDM process, in which the desirable properties of materials can be combined.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Surface Modification of 60CrMoV18-5 Steel by EDM with Cu-ZrO2 Powder Metallurgy Green Compact Electrode

et al. 2021

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Electrical discharge machining (EDM) is a non-conventional machining process, which is mostly used for machining of difficult-to-cut materials. These materials are often used in engineering applications that require improved surface properties; thus, surface modification is desirable in these cases. In the recent past, it has been observed that EDM is an alternative surface modification process due to migration of material from the electrode to the workpiece surface. Surface modification can be done with powder metallurgy (P/M) electrode as tool. The aim of this work is to examine the surface modification of the tool steel Calmax (Uddeholm) by EDM process using Cu-30 wt.% ZrO2 P/M green compact electrode. The influence of peak current (Ip) and pulse-on (Ton) on the Material Transfer Rate (MTR) and Surface Roughness (SR) was investigated and the surface characteristics were also evaluated by scanning electron microscopy (SEM). The experimental results confirm the material migration from the electrode to the machined surface and show that the higher MTR of 46.5 mgr/min is achieved on the combination of Ip = 9 A and Ton = 25 μs and the Ra varies from 3.72 μm to 7.12 μm.

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Surface modification during electrical discharge machining process – A review

Cited by 9 publications

References 31 publications

Investigation on Orbital EDM for Double-Hole Thin Wall of Integrated Flexible Joint

Investigation on Orbital EDM for Double-Hole Thin Wall of Integrated Flexible Joint

Surface Modification using Composite Electrodes in EDM: A Review

Investigation of Surface Modification of 60CrMoV18-5 Steel by EDM with Cu-ZrO2 Powder Metallurgy Green Compact Electrode

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