Article
Chemistry, Physical
Shuliang Dong, Hongchao Ji, Jian Zhou, Xianzhun Li, Lan Ding, Zhenlong Wang
Summary: Micro-liquid floated gyroscopes are widely used in military applications. However, the machining of micro-ball sockets in beryllium copper alloy is challenging due to its excellent properties. In this study, we developed a method for milling micro-ball sockets in C17200 beryllium copper alloy using micro-electrical discharge machining, achieving high precision by optimizing the machining parameters. This method provides a new way to fabricate micro-ball sockets in C17200 with high efficiency for micro-liquid floated gyroscopes.
Article
Automation & Control Systems
Xue Bai, Xi-Peng Gong, Ting-Yi Yang, Li Li
Summary: Sintered NdFeB is widely used due to its excellent magnetic properties, but its high hardness and brittleness limit its application. In this study, the sintered NdFeB was processed by electrical discharge machining milling (EDM-M) using deionized water as the dielectric medium to improve its machining properties. Comparative experiments were conducted to study the machining properties by changing the current set value. The influences of current on the material removal mechanism and surface formation mechanism were analyzed using SEM, and the characteristic of surface micro-morphology influenced by current was also analyzed. Cross-section analysis of the sintered NdFeB by DEDM-M was conducted using SEM combined with EDS. The results showed that the machining parameters of DEDM-M had a wide range, and the surface roughness was lowest under low current set value. The MRR, SR, and TWR variations were regular, indicating good controllability. Regression equations for the machining properties were obtained, and the analysis of variance was good. SEM analysis of the machined surface revealed that material removal and surface formation in DEDM-M were influenced by fusion and stress. The change of current led to differences in surface micro-morphology and affected MRR and SR. Cross-section analysis showed four categories of materials from the surface to the matrix.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Liqing Li, Yunhang Wang, Yitao Chen
Summary: Traditional liquid electric discharge machining emits a large amount of carbon, while electric discharge machining in gas, or dry EDM, offers possibilities for sustainable development. This study focuses on the servo control of dry EDM to improve discharge stability and machining efficiency. By comparing different control strategies, significant improvements were obtained in terms of discharge ratio and machining efficiency. The study also analyzed the servo characteristics under different gas media and proposed an optimization scheme. Experimental results confirmed the effectiveness of the servo strategy and the matching characteristics of different media and servos in EDM.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Shuncheng Zhou, Zhidong Liu, Yunxiao Han, Xiulei Yue, Mingbo Qiu
Summary: Traditional ECDM is a hybrid of EDM and ECM, where electrical discharge erosion and electrochemical dissolution occur simultaneously. However, reducing the recast layers is challenging due to the low ratio of electrochemical dissolution. This study proposes a novel combined machining approach called EDAM-ECM, combining electrical discharge ablation machining and ECM, using an electrolyte-oxygen aerosol. Results show that EDAM-ECM milling has higher MRR, lower REWR, and better surface quality compared to ECDM milling.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Review
Engineering, Manufacturing
Sampath Boopathi
Summary: Electrical discharge machining (EDM) is an essential unconventional electrothermal machining process that plays a crucial role in machining the contour profiles of hard materials in modern production industries. By replacing liquid dielectric fluid with gas and a small amount of liquid mixed with gas, green machining processes can be encouraged. Various gases and gas mist have been used as working fluids in dry and near-dry EDM, and extensive literature surveys have illustrated the research context, different dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques. Future research opportunities in both dry and near-dry EDM have also been summarized to promote eco-friendly EDM research activities.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Article
Engineering, Manufacturing
Shayan Bayki, Soham Mujumdar
Summary: This paper presents a 1D model for predicting the properties of EDM plasma. The model solves particle balance and energy balance equations to determine key plasma properties. Validation studies with experimental data demonstrate the model's accuracy. Simulation experiments show the impact of process parameters on plasma characteristics. The model provides valuable insights for improving productivity and energy efficiency in the dry-EDM process.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Yunxiao Han, Zhidong Liu, Mingbo Qiu, Chao Xu, Linglei Kong
Summary: By combining EDAM with ECM milling processes, the material removal rate can be significantly increased, tool wear ratio reduced, and the thickness of the recast layer decreased. The combined milling process outperformed traditional EDM milling and standalone EDAM milling in terms of efficiency and quality.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Hongwei Pan, Zhidong Liu, Mingbo Qiu, Ming Zhang, Cong Deng
Summary: A concept of multichannel discharge WEDM under semiconductor characteristics was proposed to meet the increasing demand for wire electrical discharge machining (WEDM) under extreme conditions. Experiments on high-efficiency machining with multichannel discharge showed that it can achieve high machining efficiency, enhanced surface quality, and lower wear of electrode wire. The proposed multichannel discharge WEDM sets up the foundation for the establishment of the theoretical system of EDM under semiconductor characteristics.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Moran Xu, Rong Wei, Changping Li, Tae Jo Ko
Summary: Copper-beryllium (UNS C17200) is found to have properties of flexibility, wear resistance, and high strength. A new machining method called high-frequency electrical discharge-assisted milling (HF-EDAM) was developed using copper-beryllium bundle electrodes for Inconel 718. HF-EDAM showed improved machining efficiency and surface quality compared to conventional milling (CM). This research verifies the excellent machinability of HF-EDAM based on copper-beryllium bundle electrodes, making it an effective method for high-quality and efficient machining of Inconel 718.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Changping Li, Lei Huang, Moran Xu, Yini Chen, Jielin Chen, Shujian Li, Pengnan Li, Young-Soo Choi, Tae Jo Ko
Summary: This study established a thermal-mechanical coupling cutting model to examine the processing mechanism of EDAM titanium alloy. The results revealed that increasing the temperature can reduce the material hardness, and EDAM can effectively reduce the cutting force and stress distribution on the surface of the workpiece.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Analytical
Weijing Kong, Ziyu Liu, Rudong Zhang, Yongbin Zeng
Summary: With the development of MEMS, there is an increasing demand for machining difficult-to-machine metal micro parts. Microelectric discharge machining is effective but causes recast layers. In this study, we propose wire electrochemical discharge micro-machining (WECDMM) with a new electrolyte system to remove recast layers. We optimize the electrolyte and analyze the effects of process parameters on machining quality.
Article
Engineering, Manufacturing
Satish Mullya, Ganesh Karthikeyan, Vaibhav Ganachari
Summary: In this paper, a method using slotted tool to enhance debris removal in micro-electrical discharge milling is proposed. The use of slots on the tool creates turbulence and provides space for debris accumulation, leading to increased removal rate. Experimental results validate the effectiveness of this method.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2022)
Review
Materials Science, Multidisciplinary
Xuyang Zhu, Guangxian Li, John Mo, Songlin Ding
Summary: This paper reviewed the state-of-the-art technologies applied in machining semiconductors, summarized the advantages and disadvantages of each method, introduced the latest research outcomes, and discussed the future development trend.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Mechanical
H. N. Abu Bakar, J. A. Ghani, C. H. Che Haron, M. J. Ghazali, M. S. Kasim, S. Al-Zubaidi, N. Jouini
Summary: This study investigates the tool wear mechanisms in dry and cryogenic machining of AISI H13 steel with different cutting-edge radii. The results show that cryogenic machining has longer tool life compared to dry machining, with a 55% increase in tool life when using a cutting tool with a cutting-edge radius of Rn = 0.03 mm under cryogenic conditions. Adhesive and abrasive wear are the major wear mechanisms observed, with dry machining showing more severe wear compared to cryogenic machining. These important results have promising commercial applications in the machining industry.
Article
Engineering, Mechanical
Leeba Varghese, Manesh Kailathuvalappil Kochunny, Jerin George
Summary: Micro-EDM is a non-traditional manufacturing technique that uses plasma heat energy for material removal. Optical Emission Spectroscopy is employed to calculate the plasma temperature. Mathematical modeling and analysis of plasma properties and material removal were conducted in a hybrid micro EDM process, revealing the significant impact of electrical parameters and the vital role of vibrational parameters in surface features enhancement.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2023)