Sustainable and high-efficiency green electrical discharge machining milling method

Wu, Xin; Y, Liu; Zhang, Xuexin; Dong, Hang; Zheng, Chao; Zhang, Fan; Sun, Qiang; Jin, Hui; Ji, Renjie

doi:10.1016/j.jclepro.2020.123040

Cited by 33 publications

(9 citation statements)

References 23 publications

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“…In order to improve the EDM processing efficiency and energy consumption, new power sources and new processing methods have been developed. Wu et al [5] developed a new type of power supply that combines a pulse generator and a DC power source which are isolated from each other. When EDM uses this power supply to process titanium alloys, the MRR was as high as 21494mm 3 /min, while the relative tool electrode wear rate (R-TEWR) was only 1.7%, and the energy utilization rate of the new pulse power supply was increased to 200%.…”

Section: Introductionmentioning

confidence: 99%

Experimental study and parameter optimization on sustainable and efficient machining GH4169 with rotating short arc milling method

Zhang

Han

2021

Int J Adv Manuf Technol

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Low processing efficiency and environmental pollution hinder the development of electrical discharge machining (EDM). To address this issue, a sustainable and efficient EDM method under compound field, namely rotating short arc milling, is proposed in this study. The magnetic field and high-pressure flow field of dielectric facilitate the removal of debris from discharge gap. Tap water is used as the dielectric to reduce pollutants generated during processing. Under the compound field, a portion of debris adheres to the machining end of the tool electrode to form a protective layer and participates in the discharge machining as a part of the tool electrode, which can reduce the tool electrode wear. This study describes the principles of this method to achieve high material removal rate (MRR), low tool electrode wear rate (TEWR), and environmentally friendly dielectric. Besides, a series of experiments are conducted to study the motion characteristics and resistance characteristics of rotating short arc, the influence of processing parameters on the machining performance of GH4169 superalloy. The results show that the machining voltage, machining depth, and magnetic field strength are the three most important factors that affect the efficiency and sustainability of rotating short arc milling. Furthermore, the optimal processing parameter combination is obtained by using gray relational analysis method to optimize the machining process in terms of high efficiency and environmental protection.

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Section: Introductionmentioning

confidence: 99%

Experimental study and parameter optimization on sustainable and efficient machining GH4169 with rotating short arc milling method

Zhang

Han

2021

Int J Adv Manuf Technol

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“…These disadvantages affect surface quality (Fig. 1a) and performance of the components, and in severe cases, it will cause the parts to fail [4][5]. As shown in the Fig.…”

Section: Introductionmentioning

confidence: 99%

Study on the micro-EDM processing characteristics of Ti-6Al-4V alloy with different electrode materials

Chen

Lian

et al. 2021

Int J Adv Manuf Technol

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Functional-surface microstructures are widely used in industrial practice. During the fabrication of microstructures in micro-electrical discharge machining (micro-EDM), the thermal and physical characteristics of both workpieces and electrode materials at room temperature and high temperatures have an important in uence on surface quality and distribution of recast layer. In order to study the in uence of different electrode material characteristics on the surface integrity of microstructures machined using micro-EDM, red copper, brass, copper-tungsten and tungsten electrode were used to perform micro-EDM on both Ti-6Al-4V alloy and 304 stainless steel. In the experiment, electrode with groove arrays featuring high copying accuracy and surface quality was designed to carry out powder mixed electrical discharge machining (PMEDM) on Ti-6Al-4V alloy, and the machining results were evaluated based on four indicators: microstructure morphology, tool electrode wear (TEW), material removal rate (MRR), and recast layer thickness (RLT). Simultaneously, the surface morphology and recast layer thickness changes of 304 stainless steel workpieces machined using the above four types of electrodes, using both normal polarity and negative polarity micro-EDM were quantitatively analyzed. The results showed that copper-tungsten electrode is recommended to machine Ti-6Al-4V alloy because it has a smaller TEW (139 µm), the highest MRR (255.39 mm 3 /min), and a thinner recast layer thickness (3.35 µm). This was followed by copper electrode, which featured good machining performance and machinability. When machining 304 stainless steel with negative polarity, the TEW of copper electrode and tungsten electrode was the smallest, and the thickness of recast layer was able to be effectively reduced to about 3 µm.

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“…In order to improve the EDM processing efficiency and energy consumption, researchers have conducted research on the development of new power sources and new processing methods. Wu et al (2020) has developed a new type of power supply that combines a pulse generator and a DC power source which are isolated from each other. When EDM uses this power supply to process titanium alloys, the MRR was as high as 21494mm 3 /min, while the relative tool electrode wear rate (R-TEWR) was only 1.7%, and the energy utilization rate of the new pulse power supply was increased to 200%.…”

Section: Introductionmentioning

confidence: 99%

Sustainable and Efficient Processing of Gh4169 Superalloy With Rotating Short Arc Milling Method

Zhang¹,

Han²

2021

Preprint

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High processing efficiency and low environmental pollution have been recognized as important goals of sustainable electrical discharge machining (EDM). This paper proposed a sustainable and efficient EDM method called rotating short arc milling. In order to improve the processing efficiency and reduce pollutant emissions, the principles of this method to achieve high material removal rate (MRR), low tool electrode wear rate (TEWR) and environmentally friendly dielectric are described separately. The rotating short arcs generated by the compound field can improve the machining efficiency. The action of the magnetic field and the internal high-pressure dielectric can quickly remove the debris avoiding irregular discharge, thereby improving the machining quality. Due to the attraction effect of the magnetic field on the debris, several debris adhere to the processing end of the tool electrode to form a protective layer and participates in the processing as a part of the tool electrode, which can reduce the tool electrode wear. Tap water is used as the working fluid to reduce pollutants generated during processing. Then, a series of experiments are conducted to study the influence of process parameters on the processing of GH4169 superalloy. The results show that the machining voltage, machining depth and magnetic field strength are the three most important factors that affect the efficiency and sustainability of rotating short arc milling. Furthermore, the optimal process parameters are obtained by using gray relational analysis method to optimize the machining process in terms of high efficiency and environmental protection.

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Sustainable and high-efficiency green electrical discharge machining milling method

Cited by 33 publications

References 23 publications

Experimental study and parameter optimization on sustainable and efficient machining GH4169 with rotating short arc milling method

Experimental study and parameter optimization on sustainable and efficient machining GH4169 with rotating short arc milling method

Study on the micro-EDM processing characteristics of Ti-6Al-4V alloy with different electrode materials

Sustainable and Efficient Processing of Gh4169 Superalloy With Rotating Short Arc Milling Method

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