Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V:

doi:10.1177/0954405421995605

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Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V:

Journal Article•DOI•

Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V:

Krupa Serah Jacob¹, G.L. Samuel¹•Institutions (1)

Indian Institute of Technology Madras¹

20 Feb 2021-Vol. 235, Iss: 11, pp 1832-1847

TL;DR: In this article, the authors proposed a method to mine high aspect ratio holes on Ti-6Al-4V superalloys, which is a topic of both industrial and academic interest.

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Abstract: Machining of complex features and holes on superalloys is a topic of both industrial and academic interest. Though the demand for high aspect ratio holes on Ti-6Al-4V is high in aerospace, biomedic...

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Journal Article•DOI•

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

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S. A. Mullya, G. Karthikeyan, V. S. Ganachari

31 Jan 2022-Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

TL;DR: In this article , the authors proposed the use of a slotted tool with different cross-sections and calculated the dielectric flow field, debris trajectory, and cooling rate using computational fluid dynamics (CFD).

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Abstract: In micro-electrical discharge milling (μED-milling), the rotation and forward feed motion of the tool is the key element responsible for evacuation of the debris particles. The inability to eliminate debris from the interelectrode gap (IEG) causes secondary discharge, short-circuit, and hampers removal rate. This problem is predominant in electrical discharge machining (EDM) where the tool is stationary. Various methods have been devised in the literature to boost debris removal from the IEG. In this paper, the use of a slotted tool with different cross-sections is proposed. The dielectric flow-field, debris trajectory, and cooling rate are calculated using computational fluid dynamics (CFD). Effect of different parameters such as tool rotation, gap size, jet velocity, the shape of slots on the dielectric flow is determined. The slots on the tool create turbulence which enhances the debris removal from the IEG. It also provides the space to accumulate the debris particles, thereby increasing the removal rate. The variation in the dielectric flow-field greatly affects the debris flushing from the IEG. The trajectory of the debris particles depends on their initial position in the IEG and they cool rapidly, which is validated using simulation and mathematical approach.

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1 citations

Journal Article•DOI•

Micro-EDM of 3D microstructure on micro-shaft based on the rotation of micro-shaft

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Man-qun Lian, Jianguo Liu, Xiaoyu Wu, Feng Luo, H.-X. Luo, Bin Xu - Show less +2 more

18 Jul 2022-The International Journal of Advanced Manufacturing Technology

1 citations

Journal Article•DOI•

Study on machinability of three-step drill in drilling Ti6Al4V

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Shujing Wu¹•Institutions (1)

Shandong Agricultural University¹

18 Aug 2022-Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

TL;DR: In this article , the three-step drill has changed the main cutting-edge structure, which is more conducive to chip breakage, and the results show that the improved drill has good chip breaking performance, low thrust force, and better machining performance compared with the twist drill.

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Abstract: As the research progresses, titanium alloy materials have more applications in aerospace and other fields. However, problems such as chip winding and serious tool wear are easy to occur in the machining process. In this research, the three-step drill has changed the main cutting-edge structure, which is more conducive to chip breakage. Firstly, the drilling force of the three-step drill bit is analyzed, and the alternating stress that makes the chip thickness change is obtained by the cutting-edge structure of the three-step drill bit. The simulation and experiment are verified by each other, and the feasibility of three-step drilling to improve the processing quality is obtained. The results show that the improved drill has good chip breaking performance, low thrust force, and better machining performance compared with the twist drill. In addition, the improved drill can obtain a more complete inner wall of the hole and reasonably improve the surface quality. Through experiments, it is found that changing cutting parameters such as feed rate has different effects on chip thickness, thrust and tool wear. It was found that the drilling force was reduced by drilling Ti6Al4V material with the three-step drill. Moreover, the three-step drill can produce smaller chip thicknesses and make the chip more prone to breakage when compared with the twist drill. The high wear of three-step drill bits can also be better weakened by coating materials.

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Journal Article•DOI•

Fabrication of high-accuracy micro-holes in micro-EDM under tool electrode spiral motion feed mode combined with fixed reference axial compensation

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Jun-nian Gou, Jing Yao Lai, Haoran Lin, Kang Cheung Chan, Tai We Yue, Xinlang Zuo, Zhixiang Zou, Jiangwen Liu - Show less +4 more

07 Nov 2022-The International Journal of Advanced Manufacturing Technology

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Journal Article•DOI•

Thermal stresses due to electrical discharge machining

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Vinod Yadav¹, Vijay Kumar Jain¹, P.M. Dixit¹•Institutions (1)

Indian Institute of Technology Kanpur¹

01 Jun 2002-International Journal of Machine Tools & Manufacture

TL;DR: In this paper, a finite element model has been developed to estimate the temperature field and thermal stresses due to Gaussian distributed heat flux of a spark during electrical discharge machining (EDM).

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Abstract: The high temperature gradients generated at the gap during electrical discharge machining (EDM) result in large localized thermal stresses in a small heat-affected zone. These thermal stresses can lead to micro-cracks, decrease in strength and fatigue life and possibly catastrophic failure. A finite element model has been developed to estimate the temperature field and thermal stresses due to Gaussian distributed heat flux of a spark during EDM. First, the developed code calculates the temperature in the workpiece and then the thermal stress field is estimated using this temperature field. The effects of various process variables (current and duty cycle) on temperature distribution and thermal stress distribution have been reported. The results of the analysis show high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength.

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237 citations

"Effect of micro double helical groo..." refers methods in this paper

...The high density thermal electric discharges in EDM cause the formation of recast layers and these thermal stress fields can also be predicted by making use of FEM models.(4) Studies are also driven in the direction of investigation of the relationship between accuracy and...
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Journal Article•DOI•

Intelligent process modeling and optimization of die-sinking electric discharge machining

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Shrikrishna N. Joshi¹, S. S. Pande²•Institutions (2)

Indian Institute of Technology Guwahati¹, Indian Institute of Technology Bombay²

01 Mar 2011

TL;DR: The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.

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Abstract: This paper reports an intelligent approach for process modeling and optimization of electric discharge machining (EDM). Physics based process modeling using finite element method (FEM) has been integrated with the soft computing techniques like artificial neural networks (ANN) and genetic algorithm (GA) to improve prediction accuracy of the model with less dependency on the experimental data. A two-dimensional axi-symmetric numerical (FEM) model of single spark EDM process has been developed based on more realistic assumptions such as Gaussian distribution of heat flux, time and energy dependent spark radius, etc. to predict the shape of crater, material removal rate (MRR) and tool wear rate (TWR). The model is validated using the reported analytical and experimental results. A comprehensive ANN based process model is proposed to establish relation between input process conditions (current, discharge voltage, duty cycle and discharge duration) and the process responses (crater size, MRR and TWR) .The ANN model was trained, tested and tuned by using the data generated from the numerical (FEM) model. It was found to accurately predict EDM process responses for chosen process conditions. The developed ANN process model was used in conjunction with the evolutionary non-dominated sorting genetic algorithm II (NSGA-II) to select optimal process parameters for roughing and finishing operations of EDM. Experimental studies were carried out to verify the process performance for the optimum machining conditions suggested by our approach. The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.

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126 citations

"Effect of micro double helical groo..." refers methods in this paper

...An intelligent and integrated Finite Element Method – Artificial Neural Network – Genetic Algorithm (FEM-ANN-GA) approach to optimize the die-sinking EDM process was developed with a mean prediction error of 7%.(3) The high density thermal electric discharges in EDM cause the formation of recast layers and these thermal stress fields can also be predicted by making use of FEM models....
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Journal Article•DOI•

A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications

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Hung-Sung Liu¹, Biing Hwa Yan¹, Fuang-Yuan Huang¹, Kuan-Her Qiu¹•Institutions (1)

National Central University¹

01 Dec 2005-Journal of Materials Processing Technology

TL;DR: In this article, the feasibility of fabricating micro-holes in the high nickel alloy using micro-electro-discharge machining (micro-EDM) was investigated.

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123 citations

"Effect of micro double helical groo..." refers methods or result in this paper

...This is in agreement with the findings of Liu et al.18 wherein a helical grooved electrode with added Silicon Carbide particles is used to obtain an improved surface finish....
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...In EDM though the heat affected zone is less the formation of the recast layer is one of the major drawbacks as it leads to poor surface quality and microcracks.(18) To calculate the area of the spread of the recast layer, the SEM image of the hole was imported into ImageJ software and pixel to mm conversion was done by setting the scale....
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...This is in alignment with basic principles seen in most of the literature in this field and particularly with the observations of Liu et al.18 where it is reported that the use of a helical tool for grinding a machined hole leads to good surface finish....
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...This is in agreement with the findings of Liu et al.(18) wherein a helical grooved electrode with added Silicon Carbide particles is used to obtain an improved surface finish....
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...This is in alignment with basic principles seen in most of the literature in this field and particularly with the observations of Liu et al.(18) where it is reported that the use of a helical tool for grinding a machined hole leads to good surface finish....
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Journal Article•DOI•

Using a helical micro-tool in micro-EDM combined with ultrasonic vibration for micro-hole machining

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Jung Chou Hung¹, Jui Kuan Lin², Biing Hwa Yan¹, Hung Sung Liu¹, Ping Hsing Ho¹ - Show less +1 more•Institutions (2)

National Central University¹, Industrial Technology Research Institute²

01 Dec 2006-Journal of Micromechanics and Microengineering

TL;DR: In this article, a helical micro-tool with micro ultrasonic vibration finishing (HE-MUVF) was used to drill and finish micro-holes, which can substantially reduce the EDM gap, taper and machining time for deep micro-hole drilling.

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Abstract: This paper presents a novel process using micro-electro-discharge- machining (micro-EDM) combined with ultrasonic vibration by a helical micro-tool electrode to drill and finish micro-holes. During the machining processes, a micro-tool is directly fabricated by wire electro-discharge grinding (WEDG) using micro-EDM combined with various methods for machining the micro-hole and by ultrasonic vibration to finish the hole wall. In this work, circular micro-holes are machined in a high nickel alloy by cylindrical and helical electrodes. Using a helical micro-tool electrode for micro-EDM combined with ultrasonic vibration (HE-MEDM-UV) can substantially reduce the EDM gap, taper and machining time for deep micro-hole drilling. In addition, using a helical micro-tool with micro ultrasonic vibration finishing (HE-MUVF), good surface quality and less taper of the hole wall can be obtained by applying a suitable electrode step variation, rotational speed and ultrasonic amplitude with a machining time of approximately 25 min. According to scanning electron microscopy (SEM) micrographs and atomic force microscopy (AFM) measurement, HE-MUVF can indeed improve the surface roughness from 1.345 µm Rmax before finishing to 0.58 µm Rmax after HE-MUVF. This result demonstrates that using HE-MEDM-UV combined with MUVF can yield micro-holes of precise shape and smooth surface.

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92 citations

"Effect of micro double helical groo..." refers methods in this paper

...This concept was also observed by Hung et al.(13) while performing step turning, the machining time was substantially reduced by using a single helical electrode....
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...Making use of a helical tool for micro-EDM combined with ultrasonic vibration can substantially reduce the EDM gap, variation between the entrance and exit of the hole and the machining time.(13) A novel process for fabrication of micro end mills with low-speed Wire Electric Discharge Machining (WEDM) has been developed and its feasibility for producing micro milling tools with multiple helical cutting edges has been demonstrated....
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...This concept was also observed by Hung et al.13 while performing step turning, the machining time was substantially reduced by using a single helical electrode....
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Journal Article•DOI•

Influence of flushing on performance of EDM with bunched electrode

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Lei Li¹, Lin Gu¹, Xue-Cheng Xi¹, Wansheng Zhao¹•Institutions (1)

Shanghai Jiao Tong University¹

01 Jan 2012-The International Journal of Advanced Manufacturing Technology

TL;DR: In this article, a bunched-electrode EDM with multi-hole inner flushing was proposed to achieve a higher material removal rate and lower tool wear ratio, while maintaining a lower level of tool wear.

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Abstract: The existing applications of electrical discharge machining (EDM) for bulk material removal are restricted by their comparatively low material removal rates. The bunched-electrode EDM proposed in this study, using the powerful multi-hole inner flushing, is an effective way of being released from this restriction. This paper investigates the mechanism by which flushing (flushing modes and flushing parameters) influences machining performance indices, i.e., material removal rate and tool wear rate, using experiments and simulations. Based on an investigation conducted, compared with traditional solid electrode with mono-hole inner flushing, a bunched electrode with multi-hole inner flushing endures higher peak current and results in larger material removal rate and higher relative tool wear ratio because of a more effective flushing process. By properly choosing inlet velocity and electrode effective-area ratio, a higher material removal rate is achieved and relative tool wear ratio is kept at a lower level.

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83 citations

"Effect of micro double helical groo..." refers methods in this paper

...Another comparative CFD analysis shows that the velocity increases drastically in the radial direction with a high peripheral debris concentration of 611 particles/m(2) for a mono holed electrode but for bunched electrodes the velocity field is smooth with a lower debris concentration of three particles/m(2).(16) In this work, the process of EDD is selected as it is one of the most economic and feasible ways to machine holes on superalloys and the same being an unconventional machining process produces only insignificant machining forces....
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