Effects of electrode materials on performance measures of electrical discharge micro-machining

The main objective of this study is to investigate the effects of various electrode materials and their influences on electrical discharge micro-machining performance attributes. The performance attributes are determined in terms of tool wear rate (TWR), material removal rate (MRR), taper angle, overcut, and surface roughness by drilling micro-holes on SS 316?L material. It is noticed that, for high discharge energy the MRR, TWR, taper angle, and overcut are more and also when the thermal conductivity, boiling point, and melting point of the electrode material are high, the TWR is low. The surface finish is good at low discharge energy and low spindle speed. If the tool electrode is rotating at minimum speed during machining, a centrifugal effect is created on the dielectric so that debris at the inter-electrode gap is evacuated efficiently. If the tool is stationary, then the machining conditions are unstable due to improper flushing of debris.     

Effect of tool wear on microrods fabrication using reverse μEDM

Arrayed microrods are used to drill array of microholes in workpieces by Micro electrical discharge machining (μEDM). In comparison to a single microrod, the use of an array of microrods enables drilling of multiple microholes in lesser time, and hence it offers a higher productivity. The present work focuses on the effect of tool wear on the dimensions of the machined array of microrods through reverse micro electrical discharge machining (R-μEDM). The effects of the input parameters such as voltage, capacitance and feed rate on the obtained length and diameter of the microrods have been investigated. This study introduces a simple analytical model to evaluate the amount of tool wear and material removal from a bulk rod. As the levels of voltage and capacitance increase from lower to higher, the tool wear increases by 574%. At lower levels of voltage and capacitance, a straight array of microrods with a longer length of about 1.961?mm is obtained. On the other hand, at higher levels of voltage and capacitance, the obtained microrods are found to have a shorter length of 1.725?mm but with taper. Scanning electron microscope (SEM) and optical microscope images are also analyzed for describing the effects of tool wear on the shape and size of the fabricated microrods.     

Electrical Discharge Machining of Functionally Graded 15-35 Vol% SiCp/Al Composites

A functionally Graded 15-35 volume% silicon carbide particulate (SiC_p) reinforced Al359 metal matrix composite (SiC_p/Al MMC) was drilled by electrical discharge machining (EDM) to assess the machinability and workpiece quality. The machining conditions were identified for both the machining performance and workpiece quality of the EDM process, including some aspects of material removal mechanisms, material removal rate (MRR), electrode tool wear, and subsequent drilled hole quality including surface texture and roundness by using surface profilometry, coordinate measuring machine (CMM), and scanning electron microscopy (SEM). It was observed that the material removal rate increases with increasing peak current and pulse-on-time up to the optimal points and drops drastically thereafter. Higher peak current and/or pulse-on-time result in both the greater tool wear and the larger average diameter error. As the percentage of the SiC particles increases, MRR was increased and electrode wear was found to be decreased. At the EDM machined subsurface layer, the fragmented and melted SiC particles were observed under the SEM and EDX-ray examination.     

在微细电火花铣削中介质对电极损耗的影响

在微细电火花加工（EDM）中电极损耗是不可避免的,而针对电极损耗的研究大都是在油工作液中,很少针对气中放电时的电极损耗进行研究．气中电火花加工普遍采用管状电极,所以为了获得尺寸更小的工件,通过反拷块可磨削出微米级的实心电极,并采用外部充气的方式,可实现微米级三维结构的气中电火花加工．实验考虑了影响气中放电电极损耗的各种因素．通过观察微细电火花三维铣削放电现象与结果,可得到气中放电的规律．由于电火花加工中电极损耗是不可避免的,所以在三维铣削加工中对电极进行在线检测并补偿,工件成形精度大大提高．对刀具路径进行合理规划,可以缩短加工时间．与油中电火花铣削相比,气中电火花加工时电极损耗更低,加工表面质量更好．     

Application of multi-criteria decision making methods for selection of micro-EDM process parameters

Ti-6Al-4V super alloy is an important engineering material with good strength to weight ratio and a wide range of applications in a number of engineering fields because of its excellent physical and mechanical properties.This work determines optimum process parameters such as pulse on time,peak current,gap voltage and flushing pressure,which influence the micro-electro discharge machining(EDM) process during machining of Ti-6A1-4V using combined methods of response surface methodology(RSM) and fuzzy-technique for order preference by similarity to ideal solution(TOPSIS).Central composite design(CCD) is used in the experimental investigation.A decision making model is developed to identify the optimum process parameters in the microEDM process,which influences several machining criterions such as material removal rate(MRR),tool wear rate(TWR),overcut(OC) and taper.Triangular fuzzy numbers are used to determine the weighting factor for each process criterion.Further a fuzzy-TOPSIS method is used to select the most desirable factor level combinations.The proposed technique can be used to select optimal process parameters from various sets of combinations of process parameters in a micro-EDM process.     

Experimental investigation on performance of additive mixed dielectric during micro-electric discharge drilling on 316L stainless steel

This study investigates the impact of machining factors on the performance of additive mixed micro-electric discharge drilling of 316L stainless steel. The effects of three kinds of powder, powder concentration, voltage, capacitance, feed rate, and speed on tool wear rate, material removal rate, taper angle, and overcut (OC) were also investigated. The experimental results show that adding additives to the dielectric enhanced rate of material removal and reduced rate of tool wear significantly. Mixing powder with dielectric increased the length of the sparking, resulting in significant OC, and process performance also improved with the increase in amount of powder added. Further, scanning electron microscopy analysis was carried out to examine the surface characteristics and material migration properties, which confirmed that the properties of the machined surface are indeed significantly improved.     

Effect of Cryogenic Cooling of Tool Electrode on Machining Titanium Alloy (Ti–6Al–4V) during EDM

The discharge characteristics and discharge gap of machining Ti–6Al–4V titanium alloy by cryogenically cooled tool electrode electrical discharge machining (EDM) in distilled water were investigated in this study using the monopulse discharge method. The influence of the cryogenically cooled tool electrode on the discharge gap and the initial maintaining voltage between the electrode and workpiece were analyzed under various temperatures. Test results showed the initial maintaining voltage of the cryogenically cooled tool electrode EDM was lower than that of conventional EDM. The discharge gap of the cryogenically cooled tool electrode EDM was also smaller than that of conventional EDM, which improved the copying accuracy of die-sinking EDM. A comparative experiment of machining Ti–6Al–4V titanium alloy was carried out by using cryogenically cooled tool electrode EDM and conventional EDM, lower electrode wear, higher material removal ratio, and higher corner size machining accuracy was obtained by using cryogenically cooled tool electrode EDM.     

Influence of various metal powder mixed dielectric on micro-EDM characteristics of Ti-6Al-4V

Ti-6Al-4V, an advanced engineering material is difficult-to-machine using conventional machining process due to its high strength. It has properties like low weight ratio, outstanding corrosion resistance along with high level of reliable performance in micro components. Micro-electro-discharge machining (Micro-EDM), a popular nontraditional machining process has been identified as the most appropriate machining process for such material. In this paper, the effect of various conducting powders such as copper, nickel and cobalt with different concentrations are mixed with deionized water dielectric, on various responses such as material removal rate (MRR), tool wear rate (TWR), overcut (OC) and taper has been presented. Also, principal component analysis (PCA) has been applied to select the optimal parametric combination of micro-EDM process to achieve optimal values of MRR, TWR, OC and taper during micro-through hole machining. The optimal process parametric setting obtained from the proposed approach is peak current (I_p) of 1.5 A and cobalt (Co) powder concentration of 4 g/L so as to obtain the desired responses. It is also observed from the SEM image that the machined profile and surface topography obtained through the multi-objective optimal parametric combination based on PCA is quite satisfactory and can be applied to achieve geometrically more accurate micro-through holes on Ti-6Al-4V.     

Effect of Powder Mixed Dielectric on Material Removal and Surface Modification in Microelectric Discharge Machining of Ti-6Al-4V

Microelectric discharge milling is one of the variants of microelectric discharge machining process which acquire the attention of researchers due to its unique ability to produce microchannels and three-dimensional structures in difficult-to-machine materials like titanium. In the present work, an experimental investigation has been performed in order to study the effect of SiC microparticle suspended dielectric on machining Ti-6Al-4V with tungsten carbide electrode. The effects of major electric discharge milling process parameters—voltage, capacitance, and powder concentration in dielectric—on responses—viz., material removal rate (MRR) and tool wear rate (TWR)—were studied. Experiments were designed and performed based on response surface methodology (RSM)-Box–Behnken statistical design and the significance of in put parameters were identified with the help of analysis of variance. From the results, it is recommended to use powder concentration of 5 g/L, capacitance of 0.1 µF, and voltage of 115 V for achieving high material removal and low tool wear rate. Finally, the studies were conducted to analyze the surface modification and the quality of machined surface.     

Characterization of Properties of Cryogenically Treated Al-SiC Composites Fabricated by Powder Metallurgy

The basis of this research was an exploration of the fundamental phenomena that determine the response of silicon carbide-reinforced aluminium composite material to thermal cycling between cryogenic and ambient temperatures. This analysis began with a phenomenological approach that investigated the role of the production, processing, and machining of composite materials, and led to study of their mechanical behavior at cryogenic temperatures. Electric discharge machining was done on the composite specimens and mathematical models were developed for predicting the machining parameters such as metal removal rate, tool wear rate, and surface roughness. A five-level factorial design was chosen for experimentation and mathematical models were developed using the software DOE-PC IV. An analysis of variance technique was used to calculate the regression coefficients and to check the significance of the models developed. This approach provided an understanding of how temperature and vol.% of SiC influence composite machining behavior. The hardness, wear resistance, and tensile property are high for cryo-treated specimens and these properties reduce with increase in temperature. The properties also increase with increasing % of SiC reinforcements. The microstructures of the wear specimens show worn-out layers and grooves formed in the debris. The cryo-treated and the higher reinforced specimens exhibit less material removal and tool wear rate and this increases with increase in temperature. There is a relatively higher surface roughness when there is greater material removal.     

Experimental Investigation and Optimization of Micro-EDMing Process for Silicon Substrates

Microelectrical discharge machining of n-type monocrystalline silicon is investigated in this study through a microgrooving process. The pulse duration, pulse frequency, spark current, and gap voltage are varied in the experiments. The groove geometries and roughness are measured together with the material removal rate and electrode wear ratio. The results have shown that a large and deep groove can be made at high machining rate when a high spark energy condition is applied. This can, however, increase the electrode wear ratio as a consequence, making the process inefficient. A multiresponse optimization, using Grey relational analysis, has been applied. The optimum cut result has shown that good cut quality, high material removal rate, and low electrode wear ratio are achievable from this study.     

Electrical Discharge Machining (EDM) Characteristics Associated with Electrical Discharge Energy on Machining of Cemented Tungsten Carbide

In this investigation, cemented tungsten carbides graded K10 and P10 were machined by electrical discharge machining (EDM) using an electrolytic copper electrode. The machining parameters of EDM were varied to explore the effects of electrical discharge energy on the machining characteristics, such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness. Moreover, the effects of the electrical discharge energy on heat-affected layers, surface cracks and machining debris were also determined. The experimental results show that the MRR increased with the density of the electrical discharge energy; the EWR and diameter of the machining debris were also related to the density of the electrical discharge energy. When the amount of electrical discharge energy was set to a high level, serious surface cracks on the machined surface of the cemented tungsten carbides caused by EDM were evident.     

EDM with an Air-Assisted Multi-Hole Rotating Tool

In the present research work, an extensive experimental study of air-assisted rotary electrical discharge machining (AAEDM) of high chromium, high carbon die steel has been made. Investigations have been performed to study the process factor effect namely pulse-on time, discharge current, duty cycle, tool rotation, and air pressure on material removal rate (MRR) and electrode wear ratio (EWR). A comparative analysis of solid rotary tool electrode electrical discharge machining (REDM) and AAEDM has been presented. It was found that a high MRR and low EWR occurred in AAEDM as compared to the REDM process, under the same processing conditions. Use of a multi-hole tool provided better circulation of dielectric in the discharge gap, thus it improved the flushing efficiency of the process. The results showed that the application of compressed air has a favorable influence on MRR and EWR.     

Machinability of titanium alloy through electric discharge machining

Titanium alloy (Ti-6Al-4V), being considered as hard-to-machine material, offers many challenges especially during conventional machining. Electric discharge machining could be a good option if it offers a good match between material removal rate and surface finish of the machined feature. The issue of appropriate selection of electrode material for good machining of Ti-6Al-4V is not yet comprehensively explored which is the core focus of this study. Moreover, the effect of pulse time ratio is thoroughly examined which is not specifically studied before. Discharge current and pulse time ratio are considered as the input variables, whereas the material removal rate and surface roughness are selected as performance measures of machinability. Copper, aluminum, brass and graphite are employed to evaluate the machining behavior. Experimental results revealed that aluminum electrode provides the lowest surface roughness, whereas the maximum material removal rate is achieved using graphite electrode. However, graphite electrode can offer high material removal rate with low surface roughness by initially employing negative tool polarity for rough machining and then positive tool polarity for fine machining.     

Wire EDM Mechanism of MMCs with the Variation of Reinforced Particle Size

The size of reinforced particles notably affects the electro-discharge machining (EDM) of metal matrix composites (MMCs). This paper explores the mechanism of wire EDM of MMCs with different sizes of reinforced particles as well as the corresponding unreinforced matrix material. The mechanisms of material removal, surface generation, and taper kerf formation were investigated. This study shows that the particles’ ability to protect matrix materials from the intense heat of electric arc controls the material removal rate, surface generation, and taper of kerf. The low melting point matrix material is removed very easily, but the heat resistance reinforced particles delay the removal of material and facilitate the transfer of the workpiece material to wire electrode and vice versa. Thus, the material stays longer in touch with intense heat and affects the surface generation, wire electrode wear, and width of the kerf.     

Powder Mixed Dielectric: An Approach for Improved Process Performance in EDM

The present study reports the outcome of experiments conducted to investigate the effect of parameters on improvement in the material removal rate (MRR), reduction in the tool wear rate (TWR), and overcut size for commonly used die steels. To overcome some of the shortcomings of electric discharge machining (EDM), an approach of powder mixing in dielectric fluids is adopted to investigate the influence of process parameters. The addition of powders in dielectric improves MRR and lowers TWR significantly. Powder concentration, current, and pulse-on time are three significant factors affecting MRR, TWR, and overcut size. An increase in powder concentration improves the process performance, but is limited by the possibility of arcing at higher concentration. Use of the powder resulted in increased effective spark length causing larger overcut. The problem is acute in trials conducted at high pulse-on duration with high powder concentration that leads to a ragged surface at cut edges. Furthermore, electrode tools with smaller tip included angle resulted in larger profile deviation at the machined surface as compared to trials conducted using tools with higher included angle. Surface morphological changes, grain size, microstrain, and material migration were investigated using SEM, XRD, and EDS analysis and a significant improvement in properties of the machined surface was observed.     

The Effectiveness of Multichannel Electrodes on Drilling Blind Holes on Inconel 718 by EDM Process

This study presents an experimental study on making through and blind holes on Inconel 718 by hole drilling electrical discharge machining process. Several holes of Ø2 mm were drilled at specific levels of process parameters using tubular brass electrodes having different channel configurations. Machining performances were analyzed on the basis of material removal and electrode wear. Measurements of depth, diameter, overcut, and taper of holes were performed based on scanning electron microscope photographs to evaluate geometrical and dimensional accuracies of drilled holes. Surface roughness measurements as well as energy-dispersive X-ray analyses were conducted to examine characteristics of machined hole surfaces. The research reveals that drilling holes using multichannel electrodes exhibit superior results in aspects of lower drilling time, better dimensional accuracy, and improved surface quality.     

On pressurized feeding approach for effective control on working gap in ECDM

Electrochemical discharge machining (ECDM) process is promising for machining of micro features on glass and ceramic materials. ECDM requires an effective control on process parameters for high productivity and accuracy with an increase in the depth of penetration. Among all parameter settings, the most important requirement is the effective control on working gap. The present article reports the development of pressurized feeding system for effective control on working gap during ECDM. In pressurized feeding system, the exerted pressure maintains constant working gap (almost zero) during machining, and that was provided by the development of a workpiece holding fixture. The existence of micro cavities between abrasive coated tool and work material generates thin and stable gas films underneath the tool electrode. The breakdown of these films results in high-frequency and low-intensity discharges with reduced critical voltage (V_c), and these discharges seem to be responsible for the machining of deep holes even with the use of high applied voltage. The developed pressurized feeding system exhibits 207.4% improvement in machining depth while compared to the other feeding systems. The effect of exerted pressure along with applied voltage, pulse on time, and electrolyte concentration on material removal rate, hole over cut, and taper was also investigated.     

Machining Characteristics of Inconel 718 by Sinking-EDM and Wire-EDM

Inconel 718 superalloy has wide applications in several industries due to its excellent mechanical properties. However, it is very difficult to machine using conventional cutting and grinding because of its high strength at elevated temperatures. Electrical discharge machining (EDM) is an alternative competitive process to machine Inconel alloys by electrical erosion. However, machinability and surface characteristics of EDMed Inconel surfaces are poorly understood. This study focuses on the machining characteristics of Inconel 718 by Wire-EDM and Sinking-EDM with a new Cu-SiC electrode, respectively. Material removal efficiency, surface roughness, surface topography, surface alloying, and electrode wear have been characterized. It is found that the high toughness of Inconel 718 would be the major contributing factor to the absence of microcracks on the EDMed surface. The new fabricated Cu-SiC electrode for Sinking-EDM has better performance in terms of material removal rate (MRR), surface roughness, and electrode wear. The higher melting temperature and fine microstructure of SiC contribute to the lower electrode wear of the new Cu-SiC electrode than the traditional Cu electrode.     

Multi-response optimization of the electrical discharge machining of insulating zirconia

In this study, electrical discharge machining has been used to machine insulating zirconia via the assisting electrode method. The process parameter optimization was investigated by combining the Taguchi method with grey relational analysis. The application of Taguchi–grey relational analysis is proven to effectively improve the performance of electrical discharge machining in drilling insulating zirconia. The results of this analysis indicate that the final optimal process parameters are a peak current of 8 A, a pulse duration of 16?µs, a duty cycle of 0.5, and a flushing pressure of 6?MPa. Additionally, the material removal rate, electrode wear rate, and hole taper ratio increase by 39%, 1.5%, and 1.3%, respectively, which improves the grey relational grade by 6.8%. The electrical resistance test confirms that the conductivity of the conductive layer obtained using the final optimal process parameters is better than that of the conductive layer obtained using the initial optimal process parameters. Energy spectrum analysis reveals that the conductive layer is composed of C, Cu, Zn, Zr, and O. Analysis of variance shows that the most significant component of the multi-responses is the peak current, with a 51.4% contribution.