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, Industrial
Andreas Klink, Sebastian Schneider, Thomas Bergs
Summary: Electrical discharge machining (EDM) is a versatile unconventional machining process that allows high precision manufacturing. By mechanistically linking material modification and process-induced load, model-based process design can be achieved.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Jacek Skiba, Mariusz Kulczyk, Sylwia Przybysz-Gloc, Monika Skorupska, Julita Smalc-Koziorowska, Mariusz Kobus, Kamil Nowak
Summary: This paper presents research on optimizing the unconventional plastic forming process of a copper alloy (CuCrZr) through hydrostatic extrusion (HE) and post-processing heat treatment. The study found that the post-processing treatment resulted in an improved microstructure, significantly increased hardness and strength, and maintained high electrical conductivity, thereby reducing electrode wear in the EDM process. The best results were obtained with a five-stage HE process combined with aging at 480 degrees C for 1 hour, reducing electrical discharge wear by over 50% compared to non-deformed copper electrodes.
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
Engineering, Aerospace
Jianshe Zhao, Yicong Qiu, Jian Yuan, Chao Liu
Summary: Numerical control electrical discharge machining is widely used for manufacturing closed blisk flow paths, especially for 3D curved and twisted channels. A hybrid optimization strategy based on channel grids is adopted to design the electrode trajectory and reduce the difficulty in machining curved and twisted channels. The experimental results show that the motion path generated by this method meets the requirements of machining 3D curved and twisted channels.
CHINESE JOURNAL OF AERONAUTICS
(2022)
Article
Engineering, Manufacturing
Rakesh Kumar, Vinod Yadav, Lavish Rawal, Upendra Kulshrestha
Summary: This study investigates the effect of machining input characteristics on overcut (OC) during electrical discharge machining (EDM) of nickel-based alloy Inconel 718. The results show that discharge current and pulse on time have the most significant influence on OC.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Ming Zhou, Tianshang Hu, Xin Mu, Meng Zhao, Jianwei Yang, Qing Ye, Pei Xu, Lei Yang, Fangqing Xin
Summary: To solve the difficulties of EDM machining of titanium alloys, a multivariable adaptive control system was proposed in this study. This system regulated variables such as gap voltage, electrode-discharging time, and pulse-off time to maintain suitable liquid breakdown strength for effective discharges and prevent arcing during machining. Verification tests showed that this control system was effective in severe machining situations and proved its usefulness in practical applications.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Review
Engineering, Manufacturing
Xiangzhi Wang, Chaojiang Li, Hun Guo, Songlin Ding
Summary: This paper provides an overview of methods and technologies to improve the efficiency and surface quality of PCD machining, along with their underlying mechanisms. Increasing energy utilization and sparking gap can enhance machining efficiency. Further improvements can be made by changing processing forms, dielectrics, electrode shapes, and power generators.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2022)
Article
Materials Science, Ceramics
C. Munoz-Ferreiro, C. Lopez-Pernia, R. Moriche, A. Gommeringer, F. Kern, R. Poyato, A. Gallardo-Lopez
Summary: This study investigates the feasibility of introducing graphene nanostructures with different morphologies into advanced zirconia composites and evaluating their effects under different EDM energies. The results show that stable and efficient EDM processes can be achieved in these composites using low electrode energies, with different graphene nanostructures significantly impacting their performance.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2022)
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
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
Physics, Applied
Nguyen Tien Dung
Summary: This paper presents a model for producing nano-microparticles using ultrasound-aided electric discharge. The shape and size of nickel particles were checked using scanning electron microscopy (SEM) and found to be distributed in a range of a few micrometers to 80 μm. The nickel particles were regular spherical shaped with different grain sizes. Additionally, there were many small particles attached to the surface. Various methods were employed to determine the hollow nickel particles such as very thin particles, large thickness grains, hollow sponge-like structures, and solid particles through inlay polishing, nitric acid etching, and direct SEM imaging.
MODERN PHYSICS LETTERS B
(2023)
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
Engineering, Mechanical
Sitki Akincioglu
Summary: Electrical discharge machining (EDM) was used to experiment with Titanium (Gr2) alloy, and the effects of different parameters on performance characteristics were analyzed using the Taguchi method and variance analysis. The results showed that under specific parameter conditions, better surface quality can be achieved.
FACTA UNIVERSITATIS-SERIES MECHANICAL ENGINEERING
(2022)
Article
Engineering, Manufacturing
Carmita Camposeco-Negrete
Summary: Wire electrical discharge machining is an energy-intensive process that requires correct selection of cutting parameters to optimize energy consumption, productivity, and quality. Experimental study and multi-objective optimization can reduce electricity cost and CO2 emissions, enhancing sustainability without compromising productivity and quality.
ADVANCES IN MANUFACTURING
(2021)
