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Contemporary Machining Processes for New Materials
Published in E. S. Gevorkyan, M. Rucki, V. P. Nerubatskyi, W. Żurowski, Z. Siemiątkowski, D. Morozow, A. G. Kharatyan, Remanufacturing and Advanced Machining Processes for New Materials and Components, 2022
E. S. Gevorkyan, M. Rucki, V. P. Nerubatskyi, W. Żurowski, Z. Siemiątkowski, D. Morozow, A. G. Kharatyan
EDM enables the machining of extremely hard materials, whereby complex shapes can be produced with high precision. Its inherent capability for automation is another feature fulfilling expectations of modern manufacturing. For these reasons, electrical discharge machining has become the most popular, nontraditional material removal process in today's manufacturing practice (Lauwers et al., 2012).
Vibration-Assisted EDM and Micro-EDM Processes
Published in Basil Kuriachen, Jose Mathew, Uday Shanker Dixit, Electric Discharge Hybrid-Machining Processes, 2022
Abhimanyu Singh Mertiya, Deepak Rajendra Unune
Electrical discharge machining (EDM) is an electro-thermal energy based non-traditional machining process, where electrical energy is used to generate electrical sparks and where material removal occurs mainly due to thermal energy of the spark [1]. It is one of the oldest and the most widely used unconventional machining process. It can machine any material irrespective of its hardness as long as it is electrically conductive, which is also the main criterion for selecting a material for electrical discharge machining. It is mainly used to machine difficult-to-cut materials and high strength temperature resistant alloys. EDM can be used to machine difficult and intricate geometries. It is predominantly used for producing dies and moulds. Since it does not use mechanical forces for material removal, it can be used to machine even small and delicate parts without the risk of fracture of the workpiece. Hence, it is extensively used in automotive and aerospace industries for the machining of required components. EDM also finds its use in the medical industry for making surgical implants [2].
ANFIS-Based Prediction of MRR and Surface Roughness in Electrical Discharge Machining of HAMMC
Published in Samson Jerold Samuel Chelladurai, Suresh Mayilswamy, Arun Seeralan Balakrishnan, S. Gnanasekaran, Green Materials and Advanced Manufacturing Technology, 2020
D. Mala, N. Senthilkumar, B. Deepanraj, T. Tamizharasan
EDM is a nonconventional type of machining technique in which the required shape of the workpiece is made in the tool electrode and by eroding the workpiece material around the electrode using intense sparks (electrical discharges) that are produced between the tool and workpiece (Jameson 2001). With a series of sparks that occurs between the tool and workpiece, the material is eroded between the negative and positive plattens that are parted by a fluid medium, called dielectric, which is nonconductive in nature (Lauwers et al. 2012). Generally, kerosene is the dielectric fluid used, and copper is the tool electrode material, which is also used in this experimentation. Specifications for the EDM machine used in this experiment were: maximum current of 32 Amps, maximum holding size of workpiece as 74 × 45 × 27 cm, axis travel x/y/z of 35 × 25 × 20 cm, maximum workpiece weight of 200 kg and maximum tool electrode weight of 50 kg. Generally in EDM, the effect of process parameters, such as applied current, pulse on-time, pulse off-time, gap voltage and flushing pressure, can be studied to determine the machinability behaviour of the processed material over surface roughness, tool wear rate, metal removal rate and thickness of recast layer (Yang et al. 2017).
Effect of boric acid in powder mixed EDM of Ti-6al-4V ELI
Published in Materials and Manufacturing Processes, 2023
Binoy Kumar Baroi, Promod Kumar Patowari
Ti alloys have very diverse uses in aerospace and biomedical industries. EDM is extensively used in the tool and die production industry. Generally, Gr, Al, Si, Ti, SiC, Cu, Cr, W, MoS2, TiC, Cu, TiO2, Mn, B4C, and hydroxyapatite have been used in the dielectric to enhance the machinability of the workpiece. However, use of boric acid powder to improve machinability is not found in any literature. The powder can develop a TiB coating over the surface, enhancing the workpiece’s surface characteristics. Various researchers developed boride coating using physical vapor deposition, thermal spraying, chemical vapor deposition, electrochemical coating, and so on. However, a boride coating using EDM is not found. Hence, PMEDM process can provide a boride coating over the Ti alloy using boric acid powder mixed dielectric. Boric acid powder mixed with DI water can also enhance the machining characteristics like MRR, TWR, SR, and SEC of the process. The creation of the boride and oxide layer over the workpiece makes the surface hard, wear, and corrosion resistant. These capabilities make this process very useful for industrial and bioimplant applications. Also, the use of boric powder in PMEDM is a novel one according to the literature survey.
Surface modification during hydroxyapatite powder mixed electric discharge machining of metallic biomaterials: a review
Published in Surface Engineering, 2022
Himanshu Bisaria, Bharat Bhusan Patra, Smita Mohanty
In the late seventeenth century, Sir Joseph Priestley was the first to notice the phenomenon of metal erosion caused by spark energy. During Second World War, two brothers named B.R. and N.I. Lazarenko invented a revolutionary technique for machining difficult-to-machine materials [151–154]. EDM is a cutting technique for machining electrically conductive materials that uses carefully controlled sparks between a workpiece and an electrode dipped in a dielectric liquid [155]. The electrode can be thought of as a cutting tool [156]. The CNC servo system maintains a very narrow distance between the electrode and the workpiece in dielectric fluid [157]. The material is removed in the EDM process by melting and vaporization generated by local heating. Because of the high temperature created in a narrow spark channel, material from both the workpiece and electrode melts and vaporizes [158–160]. Consequently, tiny craters appear on the workpiece's surface. EDM method is widely used in the tool and dies industry, aerospace industry, biomedical component industry, and automobile industry [161–163]. EDM method can be used to finish machining difficult-to-form materials such as superalloys, shape memory alloys, metallic biomaterials, titanium alloys, and advanced materials [164].
Constrained multi-objective optimization of EDM process parameters using kriging model and particle swarm algorithm
Published in Materials and Manufacturing Processes, 2018
Electric discharge machining (EDM) is one of the nontraditional machining methods in which the material removal process is done by the energy of electrical discharges between a tool electrode and a workpiece electrode in dielectric fluid environment. EDM is used for machining electrically conductive and hard materials to make mold and die and to fabricate automotive or aerospace components. The characteristics of EDM are low material removal rate (MRR) and high surface roughness (SR). An increase in the spark current can not only improve the MRR but also increase the SR and the electrode wear rate (EWR). The objective of maximization of MRR conflicts with the objectives of SR and EWR. Therefore, the proper selection of process parameters that simultaneously improves performances of EDM still remains a challenge [1].