Effect of Electrode Size on the Performances of Micro-EDM
TL;DR: In this article, the effect of tool electrode diameter on the micro-EDM process is discussed based on the skin effect and area effect, and it is demonstrated that the machining speed, tool wear, and taper rate are different with the increase of tool electrodes diameter.
Abstract: Understanding the effect of processing parameters on the tool electrode wear during micro-electrical discharge machining (micro-EDM) is helpful to predict and compensate the electrode wear, so as to improve the machining precision. In this paper, experiments are carried out and the influences of tool electrode diameter on the micro-EDM process are discussed based on the skin effect and area effect. It is demonstrated that the machining speed, tool wear, and taper rate are different with the increase of tool electrode diameter. Due to the skin effect and area effect, larger electrode diameter results in higher material removal rate along with higher tool wear rate. The electrode material removal increment is more than the workpiece material removal increment with the increase of tool electrode diameter, which leads to the increase of relative tool wear ratio. Discharge energy is concentrated on the tool surface which enhances the possibility of discharge on the side face and the corner of the tool electrod...
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TL;DR: A comprehensive review of the recent developments in ECDM process, its variants and their triplex hybrid methods is presented in this article, where the future research possibilities are identified and presented as research potentials.
Abstract: Electrochemical discharge machining (ECDM) is a hybrid non-conventional machining process, used to machine electrically conductive and non-conductive materials. It is a preferred process to fabricate micro scale features like micro holes, micro channels, microgrooves and 3-dimensional intricate shapes on variety of materials. In order to improve the efficacy of ECDM process, certain technical augmentations are provided with basic configuration of ECDM. These augmentations result in developments of ECDM process variants. Further, research community has developed ECDM based triplex hybrid methods for further process enrichment. This review article presents a comprehensive review of these recent developments in ECDM process, its variants and their triplex hybrid methods. The future research possibilities are identified and presented as research potentials.
126 citations
01 Apr 2019
TL;DR: In this paper, an efficient micro-machining process for the machining of non-conductive materials is described, where the miniaturized products have gain gain gain.
Abstract: Electrochemical discharge machining has been proved to be efficient micro-machining process and significantly used for the machining of non-conductive materials. The miniaturized products have gain...
50 citations
TL;DR: In this paper, a micro-size through hole electric discharge drilling (EDD) process for carbon fiber reinforced polymer matrix composites has been investigated and an aspect ratio of 10.9 was achieved by drilling a micro hole of 110μm diameter and 1.2mm depth.
44 citations
TL;DR: In the current scenario, biocompatible or biomedical materials are rising in demand for specific application requirements and its machining is one of the fundamental challenges as discussed by the authors, and many researchers fo...
Abstract: In the current scenario, biocompatible or biomedical materials are rising in demand for specific application requirements and its machining is one of the fundamental challenges. Many researchers fo...
37 citations
TL;DR: In this paper, the authors evaluated the surface integrity of micro-holes machined in stainless steel (SS304) sheet, using ultrasonic vibration-assisted micro-EDM process.
Abstract: The present research deals with the evaluation of surface integrity of micro-holes machined in stainless steel (SS304) sheet, using ultrasonic vibration-assisted micro-EDM process. Experimental results showed that pulse duration, gap voltage, and the application of ultrasonic vibration significantly affected the surface integrity in terms of the changes in recast layer thickness, micro-hardness, and the chemical composition of the machined surface. It is observed that the thickness of the recast layer is in the range of 6–23 µm, but the recast layer thickness was less with application of the ultrasonic vibration of the work piece. The heat-affected zone (HAZ) could not be observed both in FESEM and optical images. The micro-hardness in the HAZ was found in the range of 146–238 HV. The lower values of the micro-hardness were obtained with the application of vibration to the work piece. The changes in the chemical composition of the edge of the fabricated micro-holes were analyzed through EDS test, and it was found that lower amounts of carbon, oxygen, and tungsten were present in the machined surfaces.
31 citations
References
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01 Sep 1942
TL;DR: In this article, the skin effect is used to determine the surface resistivity of conductors at a wide range of frequency bands, including those of wires, transmission lines, and coils.
Abstract: At radio frequencies, the penetration of currents and magnetic fields into the surface of conductors is governed by the skin effect. Many formulas are simplified if expressed in terms of the "depth of penetration," which has merely the dimension of length but involves the frequency and the conductivity and permeability of the conductive material. Another useful parameter is the "surface resistivity" determined by the skin effect, which has simply the dimension of resistance. These parameters are given for representative metals by a convenient chart covering a wide range of frequency. The "incremental-inductance rule" is given for determining not only the effective resistance of a circuit but also the added resistance caused by conductors in the neighborhood of the circuit. Simple formulas are given for the resistance of wires, transmission lines, and coils; for the shielding effect of sheet metal; for the resistance caused by a plane or cylindrical shield near a coil; and for the properties of a transformer with a laminated iron core.
679 citations
"Effect of Electrode Size on the Per..." refers background in this paper
...The current density in the surface varies with the depth from the surface into the electrode, the expression can be given as [20]...
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...The depth of penetration d (meters) is [20]...
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...High frequency alternating currents and magnetic flux has a tendency to penetrate into the outer surface of a conductor with a limited depth, this phenomenon is called ‘‘Skin effect’’ [20]....
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TL;DR: The mechanism of material removal in EDM is based on electrical energy transfer and thermal process as discussed by the authors, however, energy transfer from electric energy into thermal energy is still an unknown topic, particularly in micro-EDM using small energy.
148 citations
"Effect of Electrode Size on the Per..." refers background in this paper
...Tool electrode wear is closely related to its electrical characteristics and thermal characteristics while it is independent of the workpiece [15]....
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TL;DR: In this article, the effect of the electrode area in the surface quality measured by the surface roughness and craters morphology was carried out for both EDM and powder-mixed dielectric.
131 citations
"Effect of Electrode Size on the Per..." refers background in this paper
...Therefore, the electrode end surface area has influence on the machined surface quality, the larger electrode end surface area results to a larger crater width and a higher surface roughness [19]....
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TL;DR: On-line estimation of tool wear is used for combining anticipated compensation with real-time compensation and extends the scope of milling EDM to the machining of blanks of which the exact shape is not known in advance.
130 citations
"Effect of Electrode Size on the Per..." refers background in this paper
...Combined with periodical measurements of electrode length, anticipated wear length can be obtained based on an off-line electrode wear model [16]....
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TL;DR: In this paper, the effect of various input parameters; current, voltage, frequency, and width, on output parameter viz., metal removal rate (MRR), tool wear rate (TWR), and overcut (OC) are studied.
Abstract: In the present work, micro-electric discharge machining (micro-EDM) of Ti-6Al-V alloy with tungsten carbide electrode has been performed. Ti-6Al-4V, which is difficult to machine via conventional machining techniques, however, can be easily machined via EDM machining, with careful selection of machining parameters for getting optimum results. In this study, the effect of various input parameters; current, voltage, frequency, and width, on output parameter viz., metal removal rate (MRR), tool wear rate (TWR), and overcut (OC) are studied. Grey relational analysis and analysis of variance (ANOVA) have been performed to optimize the levels of input parameters.
122 citations