Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview

Sabyrov, Nurbol; Jahan, Muhammad P.; Bilal, Azat; Perveen, Asma

doi:10.3390/ma12030522

Cited by 67 publications

(23 citation statements)

References 120 publications

(171 reference statements)

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“…Depending on the frequency, this process can happen several to hundreds of times in a second, thus creating multiple overlapping craters. Although the EDM process is a combination of different phenomena, such as dielectric break down, plasma formation, heat conduction, fluid dynamics, electrical phenomenon, chemical phenomenon, etc., thermal effects with a small error can be considered as the dominating phenomenon in the EDM process [1][2][3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process. Machines 2019, 7, 47 2 of 17 model where the problem of heat conduction for both infinite and semi-infinite bodies with a constant heat source was solved. DiBitonto et al. [7] developed a point heat source cathode erosion model. Since spherical symmetry was considered in their model, the heat transfer equation in spherical coordinates was implemented. In their model, the constant cathode energy fraction of 0.183 was assumed. In their subsequent study [8], they developed an anode erosion model, by assuming a disk heat source. Beck et al.[9] developed a model to find the temperature distribution of a semi-infinite cylinder with a constant heat source and an insulated boundary. Since this model was not developed particularly for the EDM process, the heat fraction to the workpiece is not considered.Process performances of EDM have been investigated by many researchers. D'Urso et al.[10] defined a process index based on process parameters and material properties to analyze the process and geometric indexes of micro-EDM process. D'Urso and Ravasio [11], based on a material-technology index (MTI), studied the process performance of micro-EDM. Tsai and Masuzawa [12] analyzed the electrode wear of different electrode materials in a micro-EDM process. Based on experimental results, a new wear resistance index based on modified boiling and melting points for the evaluation of erosion performance was proposed. Marafona and Araujo [13] proposed an additive model to investigate the influence of hardness on the material removal rate and surface roughness. Alshemary et al. [14] studied effects of different process parameters on fabricating cylindrical holes by wire-EDM. Mandal et al. [15] investigated the surface integrity of wire-EDM. They reported that both grinding and etching-grinding techniques removed the recast layer, and hence improved the surface integrity. Prakash et al. [16] proposed altering the EDM process for coating TiO 2 -T...

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Section: Introductionmentioning

confidence: 99%

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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“…The parameters of electrical discharge (discharge voltage, discharge current, and time pulse) determine the value of discharge energy. These parameters directly affect the surface integrity and material removal rate (MRR) [7,8,9,10]. The processing condition, type of dielectric, and electrode and workpiece material also have a strong influence on the quality of parts after EDM [11,12,13,14].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Świercz¹,

Oniszczuk-Świercz²

2019

Materials

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Electrical discharge machining (EDM) is an advanced technology used to manufacture difficult-to-cut conductive materials. However, the surface layer properties after EDM require additional finishing operations in many cases. Therefore, new methods implemented in EDM are being developed to improve surface characteristics and the material removal rate. This paper presents new research about improving the surface integrity of 55NiCrMoV7 tool steel by using reduced graphene oxide (RGO) flakes in the dielectric. The main goal of the research was to investigate the influence of RGO flakes in the dielectric on electrical discharge propagation and heat dissipation in the gap. The investigation of the influence of discharge current I and pulse time ton during EDM with RGO flakes in the dielectric was carried out using response surface methodology. Furthermore, the surface texture properties and metallographic structure after EDM with RGO in the dielectric and conventional EDM were investigated and described. The obtained results indicate that using RGO flakes in the dielectric leads to a decreased surface roughness and recast layer thickness with an increased material removal rate (MRR). The presence of RGO flakes in the dielectric reduced the breakdown voltage and allowed several discharges to occur during one pulse. The dispersion of the discharge caused a decrease in the energy delivered to the workpiece. In terms of the finishing EDM parameters, there was a 460% reduction in roughness Ra with a uniform distribution of the recast layer on the surface, and a slight increase in MRR (12%) was obtained.

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“…This technique has shown promising increases in MRR [13], a higher process efficiency [25] and significant improvements in the obtainable surface quality in EDM finishing operations [26]. Although ultrasonic assisted EDM processes are widely used in industry, further investigation is still needed to help understand the ultrasonic vibration-assisted EDM process, dominant variables, process modelling and optimization, especially its application to deep micro/conventional drilling [27].…”

Section: State-of-the-art Flushing Approachesmentioning

confidence: 99%

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Goiogana

Elkaseer

2019

Materials

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This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

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Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview

Cited by 67 publications

References 120 publications

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

Investigation of the Influence of Reduced Graphene Oxide Flakes in the Dielectric on Surface Characteristics and Material Removal Rate in EDM

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

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