Surface characterization and material migration during surface modification of die steels with silicon, graphite and tungsten powder in EDM process

The present study reports the results of an experimental work carried out to evaluate the improvement in machined surface properties of die steels machined using powder mixed electric discharge machining (PMEDM) process. Two surface responses, surface finish and microhardness were analyzed for changes when machined with Si, W and graphite powders mixed in dielectric fluid. The machined surfaces were subsequently analyzed using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) to study the element migration from powder, dielectric and the tool. The powder mixed with dielectric and its concentration, current and pulse on time were identified as the significant factors affecting surface finish. Brass electrode and tungsten powder resulted in good surface finish. Amongst the dielectrics used, kerosene provided a better cooling effect whereas EDM oil resulted in better surface finish. The microhardness of the machined surface was also affected by powder and its concentration, current, pulse on time and electrode material. W-Cu electrode and W powder resulted in a higher microhardness. The SEM and EDS analysis showed significant migration of material from the suspended powder, electrode and dielectric to the machined surface.     

Modeling and analysis of white layer depth in a wire-cut EDM process through response surface methodology

A white layer is considered a major flaw on a workpiece surface machined with wire-cut electrical discharge machining (WEDM). In this paper, an attempt has been made to model the white layer depth through response surface methodology (RSM) in a WEDM process comprising a rough cut followed by a trim cut. An experimental plan for rotatable central composite design of second order involving four variables with five levels has been employed to carry out the experimental investigation and subsequently to establish the mathematical model correlating the input process parameters with the response. Pulse on time during rough cutting, pulse on time, wire tool offset, and constant cutting speed during trim cutting are considered the dominant input process parameters whilst the white layer depth is the response. An insignificant lack of fit term indicated a curve with a good fit. Also, an extensive analysis of the influences of all the individual input parameters on the response has been carried out and presented in this research study.     

EDM更快速的加工工艺

EDM加工的复杂性难于控制，本文介绍一些在这方面提高工作速度和改善性能的进展。     

Analysis of micro-scale EDM process

A micro EDM model is proposed along with numeric simulation and experimental validation. The work is aimed at relating input/output parameters towards the establishment of a possible process model. It makes use of dimensionless groups related and relevant to micro electro discharges and their effect on metal removal during the process. The reasons for their selection are discussed and problems related to micro discharges are explained. An electric circuit used for the controlling of the discharge is presented and explained. A specific output is used as an example for the model, as suggested.     

Detection of the eroding surface in the EDM process based on the current signal in the gap

To achieve high removal rate and low electrode wear in sinking electrical discharge machining process (EDM), rough machining parameters have to be selected according to the size of the eroding surface. In general, the size of the eroding surface varies according to the depth of the machining. Thus, it has to be determined on-line. This paper shows that the electric current signal in the gap depends on the size of the eroding surface. The significance of the process attributes of the electric current signal is established by inductive machine learning and the general decision rules are derived. The size of the eroding surface can be detected on-line by monitoring and evaluating the electric current signal in the gap.     

Detection of the eroding surface in the EDM process based on the current signal in the gap

To achieve a high removal rate and low electrode wear in a sinking electrical discharge machining process (EDM), rough machining parameters have to be selected according to the size of the eroding surface. In general, the size of the eroding surface varies according to the depth of the machining. Thus, it has to be determined on-line. This paper shows that the electric current signal in the gap depends on the size of the eroding surface. The significance of the process attributes of the electric current signal is established by inductive machine learning and the general decision rules are derived. The size of the eroding surface can be detected on-line by monitoring and evaluating the electric current signal in the gap.     

Study of the heat transfer performance of gravity heat pipes based on lattice Boltzmann surface modification

Journal of Mechanical Science and Technology - Surface modification is an important means to improve boiling heat transfer. Based on the research of surface wettability, this paper briefly...     

Optimization of EDM process for multiple performance characteristics using Taguchi method and Grey relational analysis

Electrical discharge machining (EDM) is one of the most extensively used non-conventional material removal processes. The Taguchi method has been utilized to determine the optimal EDM conditions in several industrial fields. The method, however, was designed to optimize only a single performance characteristic. To remove that limitation, the Grey relational analysis theory has been used to resolve the complicated interrelationships among the multiple performance characteristics. In the present study, we attempted to find the optimal machining conditions under which the micro-hole can be formed to a minimum diameter and a maximum aspect ratio. The Taguchi method was used to determine the relations between machining parameters and process characteristics. It was found that electrode wear and the entrance and exit clearances had a significant effect on the diameter of the micro-hole when the diameter of the electrode was identical. Grey relational analysis was used to determine the optimal machining parameters, among which the input voltage and the capacitance were found to be the most significant. The obtained optimal machining conditions were an input voltage of 60V, a capacitance of 680pF, a resistance of 500Ω, the feed rate of 1.5μm/s and a spindle speed of 1500rpm. Under these conditions, a micro-hole of 40μm average diameter and 10 aspect ratio could be machined.     

用自制总积分散射仪进行SiC基底表面改性效果评估

根据总积分散射理论和工程需要自制了半球式总积分散射仪,并应用其对SiC基底表面改性的效果进行检测和评估。其优点是操作简单,方便快捷,不接触样品,对表面无损害。通过对测试数据的分析和与分光光度计的对比可知,从散射特性角度对SiC基底表面改性效果进行评估是合理有效的,该总积分散射仪的测试结果是准确可靠的。     

Taguchi analysis of surface modification technique using W-Cu powder metallurgy sintered tools in EDM and characterization of the deposited layer

The present study describes an experimental research on surface modification during electrical discharge machining (EDM) by depositing a hard layer over the work surface of C-40 grade plain carbon steel using specially prepared powder metallurgy compact tools. The investigated process parameters were composition, compaction pressure, sintering temperature, pulse on-time, peak?Ccurrent setting, and duty factor. Measurements of deposited layer thickness, mass transfer rate, tool wear rate, surface roughness and microhardness were undertaken on the EDM-ed specimens. Different studies like X-ray diffraction, optical microscopy, scanning electron microscopy, and energy dispersive X-ray spectroscopy were carried out to ascertain the characteristics of the deposited layer on the work surface. These analyses confirmed the presence of the tool materials in the work surface layer. At first, an L-16 orthogonal array was applied as Taguchi DOE technique and the ANOVA was done to study the effects of pertinent process parameters. An optimum condition was achieved using overall evaluation criteria. Later on, a detailed study was carried out to get a smooth and regular deposition of material. The characterization of the deposited layer is presented. The deposited layer with a wide range of average layer thickness of 3?C785???m, enriched with tool materials (W and Cu) and with the formation of tungsten carbide, and having microhardness of 9.81?C12.75?GPa at the hardest zone was successfully deposited over the work surface.     

一种提高空间用RB-SiC基底反射镜表面改性效果的有效方法

为了满足空间应用中大口径、复杂轻量化结构的RB-SiC基底反射镜对高性能表面质量的应用需求,针对RB-SiC基底的特性,改进了表面改性工艺方法。采用高能量考夫曼离子源辅助,预先对基底进行碳化和加镀C缓冲层,并制备Si改性涂层的方法对RB-SiC基底进行了表面改性。测试结果表明：与单纯霍尔离子源辅助方法相比,此工艺方法制备的Si改性涂层生长得更加致密、均匀,抛光特性良好;改性抛光后表面粗糙度（rms）降低到0.635nm,已达到S-SiC基底的水平;改性后RB-SiC基底的反射率明显提高,已经达到抛光良好的微晶玻璃的水平。结果表明该工艺方法是提高RB-SiC基底表面改性效果的一种十分合理有效的方法。     

RB-SiC基底反射镜表面改性工艺的改进

为了满足空间用大口径、复杂轻量化结构RB-SiC基底反射镜对高性能表面质量的需求,针对RB-SiC基底的特性,提出了改进表面改性工艺的方法.采用高能量考夫曼离子源辅助,预先对基底进行碳化和加镀C缓冲层,并制备Si改性涂层的方法对RB-SiC基底进行了表面改性.测试结果表明:与单纯霍尔离子源辅助方法相比,该工艺方法制备的Si改性涂层生长得更加致密、均匀,抛光特性良好;改性抛光后表面粗糙度(rms)降低到0.635 nm,达到了S-SiC基底的水平;改性后RB-SiC基底的反射率明显提高,达到了抛光良好的微晶玻璃的水平.结果表明,该工艺方法是提高RB-SiC基底表面改性效果的一种合理有效的方法.     

逆向分层自动添加支撑的算法与实现

分析了快速原型中支撑对成型实体及成型过程影响，在必须添加支撑时，根据支撑与成型实体的几何依赖关系，采用在逆向分层的过程中自动添加支撑的方法。该算法从选定的零件分层方向的最高顶点开始向下逆向分层或从零件层片文件的最后一层向前读入层片文件，在分层过程中或读入层片文件过程中快速而准确获得成型任意形状的层片轮廓零件所必需的支撑；提出采用轮廓偏置的方法确定是否添加支撑。本算法与传统的算法相比可以最大限度地避免或减少所需的支撑添加，同时克服了传统支撑算法中的重复运算，有效地提高了快速成型中前置数据处理的效率。     

Roughness of the machined surface in wire EDM

Wire electric-discharge machining (EDM) is investigated. A complete factorial experiment is conducted. Regression methods are used in analysis of the experimental results and the derivation of an empirical formula. The empirical model obtained permits assessment of how the roughness of the machined surface depends on the cutting conditions, the height of the workpiece, and its properties.     

电火花小孔加工速度的工艺试验研究

简述电火花小孔加工试验原理及系统构成,并分析了工件材料的热物理系数、平均功率及脉冲宽度等参数对电火花小孔加工速度的影响,为实际应用提供了重要参考。     

Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

In this study, thermal modeling and finite element simulation of electrical discharge machining (EDM) has been done, taking into account several important aspects such as temperature-dependent material properties, shape and size of the heated zone (Gaussian heat distribution), energy distribution factor, plasma flushing efficiency, and phase change to predict thermal behavior and material removal mechanism in EDM process. Temperature distribution on the cathode has been calculated using ANSYS finite element code, and the effect of EDM parameters on heat distribution along the radius and depth of the workpiece has been obtained. Temperature profiles have been used to calculate theoretical material removal rate (MRR) from the cathode. Theoretically calculated MRRs are compared with the experimental results, making it possible to precisely determine the portion of energy that enters the cathode for AISI H13 tool steel. Also in this paper, the effect of EDM parameters on MRR has been investigated by using the technique of design of experiments and response surface methodology. Finally, a quadratic polynomial regression model has been proposed for MRR, and the accuracy of this model has been checked by means of analysis of residuals.     

Numerical study on the splitting of a vapour bubble in the process of EDM

Electrical discharge machining (EDM) is a powerful technique for machining of hard and brittle materials. In this process, because of electrical discharge, a vapour bubble is generated in the dielectric liquid between the tool and the workpiece. The growth and collapse phases of the vapour bubble have significant effect on the hydrodynamic behaviour of the dielectric liquid domain between the tool and the workpiece and cause molten material to escape from the crater. Previous numerical studies on the dynamics of an electrical discharge-generated vapour bubble have simulated the growth and collapse of the bubble until it has taken the shape of an hour-glass. This is necking phenomenon which is followed by splitting of the bubble into two parts. In this paper dynamics of an electrical discharge-generated vapour bubble between the tool and the workpiece after its splitting are investigated by using the boundary integral equation method. Development of a liquid jet on the boundary of the each of the upper and lower parts of the bubble and the impingement of the liquid jets on the nearby rigid surfaces are sought. This paper consists of two parts. In part one, the vapour bubble is initially located between the tool and the workpiece. Consequently the dynamic behaviour of the two parts of the bubble in the absence of the buoyancy forces are symmetric with respect to a horizontal axis through the mid-point between the tool and the workpiece. In part two, the elrecrical discharge-generated vapour bubble is initially located in the vicinity of the workpiece. Therefore during the necking phenomenon the upper part of the bubble is smaller than its lower part. Consequently the dynamic behaviour of the two parts of the bubble after its splitting are significantly different.