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Electrical discharge machining

About: Electrical discharge machining is a(n) research topic. Over the lifetime, 13334 publication(s) have been published within this topic receiving 147523 citation(s). The topic is also known as: electrodischarge machining.

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Journal ArticleDOI
Abstract: Electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult-to-machine by conventional machining processes. The non-contact machining technique has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests. In recent years, EDM researchers have explored a number of ways to improve the sparking efficiency including some unique experimental concepts that depart from the EDM traditional sparking phenomenon. Despite a range of different approaches, this new research shares the same objectives of achieving more efficient metal removal coupled with a reduction in tool wear and improved surface quality. This paper reviews the research work carried out from the inception to the development of die-sinking EDM within the past decade. It reports on the EDM research relating to improving performance measures, optimising the process variables, monitoring and control the sparking process, simplifying the electrode design and manufacture. A range of EDM applications are highlighted together with the development of hybrid machining processes. The final part of the paper discusses these developments and outlines the trends for future EDM research.

1,274 citations

Journal ArticleDOI
Abstract: Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporising. The electrode and the work piece must have electrical conductivity in order to generate the spark. There are various types of products which can be produced using EDM such as dies and moulds. Parts of aerospace, automotive industry and surgical components can be finished by EDM. This paper reviews the research trends in EDM on ultrasonic vibration, dry EDM machining, EDM with powder additives, EDM in water and modeling technique in predicting EDM performances.

668 citations

Journal ArticleDOI
Abstract: This paper aims to compare the material removal rate, ν between a Dimensional Analysis (DA) model, an Artificial Neural Network (ANN) model and an experimental result for a low gap current of an Electrical Discharge Machining (EDM) process. The data analysis is based on a copper electrode and steel workpiece materials. The DA and ANN model that have been developed and reported earlier by authors are used to compare the material removal of EDM process. The result indicated that the ANN model provides better accuracy towards the experimental results.

612 citations

Journal ArticleDOI
Abstract: Wire electrical discharge machining (WEDM) is a specialised thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilising the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Over the years, the WEDM process has remained as a competitive and economical machining option fulfilling the demanding machining requirements imposed by the short product development cycles and the growing cost pressures. However, the risk of wire breakage and bending has undermined the full potential of the process drastically reducing the efficiency and accuracy of the WEDM operation. A significant amount of research has explored the different methodologies of achieving the ultimate WEDM goals of optimising the numerous process parameters analytically with the total elimination of the wire breakages thereby also improving the overall machining reliability. This paper reviews the vast array of research work carried out from the spin-off from the EDM process to the development of the WEDM. It reports on the WEDM research involving the optimisation of the process parameters surveying the influence of the various factors affecting the machining performance and productivity. The paper also highlights the adaptive monitoring and control of the process investigating the feasibility of the different control strategies of obtaining the optimal machining conditions. A wide range of WEDM industrial applications are reported together with the development of the hybrid machining processes. The final part of the paper discusses these developments and outlines the possible trends for future WEDM research.

575 citations

Journal ArticleDOI
Abstract: A simple cathode erosion model for the electrical discharge machining (EDM) process is presented. This point heat‐source model differs from previous conduction models in that it accepts power rather than temperature as the boundary condition at the plasma/cathode interface. Optimum pulse times are predicted to within an average of 16% over a two‐decade range after the model is tuned to a single experimental point. A constant fraction of the total power supplied to the gap is transferred to the cathode over a wide range of currents. A universal, dimensionless model is then presented which identifies the key parameters of optimum pulse time factor (g) and erodibility (j) in terms of the thermophysical properties of the cathode material. Compton’s original energy balance for gas discharges is amended for EDM conditions. Here it is believed that the high density of the liquid dielectric causes plasmas of higher energy intensity and pressure than those for gas discharges. These differences of macroscopic diele...

517 citations

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