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

doi:10.1177/0954405421995605

Home
/
Papers
/
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.

read less

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...

...read moreread less

Citations

PDF

Open Access

More filters

Journal Article•DOI•

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

[...]

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).

...read moreread less

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.

...read moreread less

1 citations

Journal Article•DOI•

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

[...]

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

[...]

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.

...read moreread less

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.

...read moreread less

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

[...]

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

References

PDF

Open Access

More filters

Journal Article•DOI•

Micro-electrical discharge machining of difficult-to-machine materials: A review:

[...]

Ved Prakash¹, Pankaj Kumar¹, Purushottam Kumar Singh¹, Manowar Hussain¹, Alok Kumar Das¹, Somnath Chattopadhyaya¹ - Show less +2 more•Institutions (1)

Indian Institutes of Technology¹

01 Jan 2019

TL;DR: Electrical discharge machining has emerged as one of the most accepted non-traditional machining methods that have the capability of attaining complex shapes and better feature size in difficult-to-reach environments as discussed by the authors.

...read moreread less

Abstract: Electrical discharge machining has emerged as one of the most accepted non-traditional machining methods that have the capability of attaining complex shapes and better feature size in difficult-to...

...read moreread less

74 citations

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

...Micro Electric Discharge Machining (EDM) is a widely accepted and economical way of fabricating micro features, especially micro holes.(2) Of late, much of the research in the field of EDM is focused on developing multi-objective optimization techniques to obtain better Material Removal Rate (MRR) and surface finish....
[...]

Journal Article•DOI•

A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718

[...]

M. Tanjilul¹, Afzaal Ahmed¹, A. Senthil Kumar¹, M. M. Rahman¹•Institutions (1)

National University of Singapore¹

01 May 2018-Journal of Materials Processing Technology

TL;DR: In this article, the authors present an innovative simultaneous flushing and vacuum-assisted debris removal system, which facilitates better debris removal for deep-hole electrical discharge machining (EDM) drilling, which is often used for drilling holes in difficult-to-cut materials such as Nickel-based super alloys.

...read moreread less

69 citations

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

...Comparative studies with the conventional process showed that vacuum-assisted drilling provided a stable gap voltage and lesser retraction frequency of the electrode.(7) An observation of flushing behavior by particle velocimetry tracking and its confirmation by computational fluid dynamics (CFD) simulation showed that the prime factor affecting the debris trajectory was the outflow of dielectric from the electrode....
[...]

Journal Article•DOI•

Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf

[...]

Akira Okada¹, Yoshiyuki Uno¹, S. Onoda¹, Sameh Habib²•Institutions (2)

Okayama University¹, Banha University²

01 Jan 2009-CIRP Annals

TL;DR: In this paper, the influence of flow rate of working fluid from nozzles and the nozzle stand-off distance on flow field in the kerf and debris particle motion were analyzed by computational fluid dynamics (CFD) simulation.

...read moreread less

59 citations

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

...CFD investigations on flow velocity and stagnation area of debris during WEDM show that the direction of debris movement is in the direction of the jet with the highest velocity and there exists a debris stagnation area irrespective of the flushing method and regardless of the nozzle standoff distance.(15) 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)....
[...]

Journal Article•DOI•

Electric discharge drilling of micro holes in CFRP laminates

[...]

Ravinder Kumar¹, Ankita Kumar¹, Inderdeep Singh¹•Institutions (1)

Indian Institute of Technology Roorkee¹

01 Sep 2018-Journal of Materials Processing Technology

TL;DR: In this paper, a tungsten carbide electrode of diameter 120μm was used as a tool electrode and several experiments were conducted using different tool geometries (i.e., solid, single notch and double notch) at different values of voltage, capacitance and tool speed.

...read moreread less

39 citations

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

...Tools having peripheral micro-slots with an angle of 60 or 75 assists the debris removal from the machining zone and the tool acts as a self-flushing electrode.(10) Deep slotted electrodes improved the MRR during large scale EDM by 91% and during machining of a helispherical feature by 116....
[...]

Journal Article•DOI•

Design and Optimization of Machining Parameters for Effective AISI P20 Removal Rate during Milling Operation

[...]

Ilesanmi Daniyan, Isaac Tlhabadira¹, O.O. Daramola², O.O. Daramola¹, Khumbulani Mpofu - Show less +1 more•Institutions (2)

Tshwane University of Technology¹, Federal University of Technology Akure²

01 Jan 2019-Procedia CIRP

TL;DR: In this paper, the milling process was designed to optimize the effects of machining parameters namely; the width of cut, cutting force, depth of cut and feed rate for effective AISI P20 removal during milling operation.

...read moreread less

33 citations

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

...This phenomena in EDM drilling is analogous to the chip evacuation velocity observed in milling.(20) At smaller helix angles, the axial component of the flow Figure 12....
[...]