nach oben

Arabian Journal for Science and Engineering

Erschienen in:

03.02.2023 | Research Article-Mechanical Engineering

An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance

verfasst von: Kamlesh Paswan, Alokesh Pramanik, Somnath Chattopadhyaya, Shubham Sharma, Gurminder Singh, Aqib Mashood Khan, Sunpreet Singh

Erschienen in: Arabian Journal for Science and Engineering | Ausgabe 9/2023

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

In this work, a highly carbonated liquid has been utilized as a dielectric medium in the EDM process. The effect of the dielectric medium has been investigated and then, finally, compared with EDM oil. The outcomes have demonstrated that discharge energy density has escalated to fierce-extent, thus, removing a voluminous amount of material from the workpiece. The results also emphasize that the dielectric medium has a viscosity (8.6 CS) higher than EDM oil (2.16 CS) is helpful for higher MRR. The debris particle has remained suspended in the dielectric medium due to its highly viscous properties leading to high MRR without any flushing technique. The process parameters, pulse-on-time, and peak current have dramatically influenced the EDM process. Further, the surface morphology has also been investigated. Results have also revealed that at a low peak current value, the MRR has increased by 155.55%, whereas, at a low value of pulse-on-time, MRR has decreased by 28.25%. At a high peak current value, MRR has increased by 217.55%, whereas, at a high value of pulse-on-time, MRR has increased by 324.05%. The highly carbonated liquid dielectric has considered the most suitable dielectric medium for high discharge energy. Micro-crack density and size have increased with MRR because of highly concentrated discharge energy. The recast layer thickness has increased with the dielectric medium's viscosity because of improper molten metal flushing, and the molten metal re-solidifies on the same surface.

Vorheriger Artikel Finite Element Simulation of Double-Nosing Process for Manufacturing of the Special Engine Shell

Nächster Artikel A simplified dynamic model to reveal mechanical characteristic of load wheel and experimental validation

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Sanchez, J.A.; Plaza, S.; De Lacalle, L.N.L.; Lamikiz, A.: Computer simulation of wire-EDM taper-cutting. Int. J. Comput. Integr. Manuf. 19, 727–735 (2006). https://doi.org/10.1080/09511920600628855CrossRef

Tsai, H.C.; Yan, B.H.; Huang, F.Y.: EDM performance of Cr/Cu-based composite electrodes. Int. J. Mach. Tools Manuf. 43, 245–252 (2003). https://doi.org/10.1016/S0890-6955(02)00238-9CrossRef

Paswan, K.; Chattopadhyaya, S.; Pramanik, A.: Effect of composition and grain structure on machining performance in EDM-A review. IOP Conf. Ser. Mater. Sci. Eng. (2018). https://doi.org/10.1088/1757-899X/377/1/012070CrossRef

Pramanik, A.; Basak, A.K.; Islam, M.N.: Effect of reinforced particle size on wire EDM of MMCs. Int. J. Mach. Mach. Mater. 17, 139 (2015). https://doi.org/10.1504/IJMMM.2015.070918CrossRef

Prakash, V.; Shubham, K.P.; Singh, P.K.; Das, A.K.; Chattopadhyaya, S., et al.: Surface alloying of miniature components by micro electrical discharge process. Mater. Manuf. Process. 33, 1051–1061 (2018). https://doi.org/10.1080/10426914.2017.1364755CrossRef

Niamat, M.; Sarfraz, S.; Aziz, H.; Jahanzaib, M.; Shehab, E.; Ahmad, W., et al.: Effect of different dielectrics on material removal rate, electrode wear rate and microstructures in EDM. Procedia CIRP 60, 2–7 (2017). https://doi.org/10.1016/j.procir.2017.02.023CrossRef

Tariq, J.S.: Experimental Investigation into the performance of water as dielectric in EDM. Int. J. Mach. Tool Des. Res. 24, 31–43 (1984)CrossRef

Tao, J.; Shih, A.J.; Ni, J.: Near-dry EDM milling of mirror-like surface finish. Int. J. Electr. Mach. 13, 29–33 (2008)CrossRef

Kung, K.Y.; Horng, J.T.; Chiang, K.T.: Material removal rate and electrode wear ratio study on the powder mixed electrical discharge machining of cobalt-bonded tungsten carbide. Int. J. Adv. Manuf. Technol. 40, 95–104 (2009). https://doi.org/10.1007/s00170-007-1307-2CrossRef

10.

Syed, K.H.; Kuppan, P.: Studies on recast-layer in EDM using aluminium powder mixed distilled water dielectric fluid. Int. J. Eng. Technol. 5, 1775–1780 (2013)

11.

Govindan, P.; Joshi, S.S.: Experimental characterization of material removal in dry electrical discharge drilling. Int. J. Mach. Tools. Manuf. 50, 431–443 (2010). https://doi.org/10.1016/j.ijmachtools.2010.02.004CrossRef

12.

Kunieda, M.; Furuoya, S.; Taniguchi, N.: Improvement of EDM efficiency by supplying oxygen gas into gap. CIRP Ann. Manuf. Technol. 40, 215–218 (1991). https://doi.org/10.1016/S0007-8506(07)61971-4CrossRef

13.

Dhakar, K.; Dvivedi, A.; Dhiman, A.: Experimental investigation on effects of dielectric mediums in near-dry electric discharge machining. J. Mech. Sci. Technol. 30, 2179–2185 (2016). https://doi.org/10.1007/s12206-016-0425-xCrossRef

14.

Guu, Y.H.; Hocheng, H.; Chou, C.Y.; Deng, C.S.: Effect of electrical discharge machining on surface characteristics and machining damage of AISI D2 tool steel. Mater. Sci. Eng. A 358, 37–43 (2003). https://doi.org/10.1016/S0921-5093(03)00272-7CrossRef

15.

Gerasimov, A.I.: Water as an insulator in pulsed facilities (review). Instrum. Exp. Tech. 48, 141–167 (2005). https://doi.org/10.1007/s10786-005-0029-7CrossRef

16.

Jeswani, M.L.L.: Electrical discharge machining in distilled water. Wear 72, 81–88 (1981). https://doi.org/10.1016/0043-1648(81)90285-4CrossRef

17.

König, W.; Jörres, L.: Aqueous solutions of organic compounds as dielectrics for EDM sinking. CIRP Ann. Manuf. Technol. 36, 105–109 (1987). https://doi.org/10.1016/S0007-8506(07)62564-5CrossRef

18.

Ekmekci, B.: Residual stresses and white layer in electric discharge machining (EDM). Appl. Surf. Sci. 253, 9234–9240 (2007). https://doi.org/10.1016/j.apsusc.2007.05.078CrossRef

19.

Ayesta, I., et al.: Experimental study on debris evacuation during slot EDMing. Procedia CIRP 42, 6–11 (2016)CrossRef

20.

Kunieda, M.; Masuzawa, T.: A fundamental study on a horizontal EDM. CIRP Ann. Manuf. Technol. 37(1), 187–190 (1988)CrossRef

21.

Maccarini, G.; Pellegrini, G.; Ravasio, C.: Effects of the properties of workpiece, electrode and dielectric fluid in micro-EDM drilling process. Procedia Manuf. 51, 834–841 (2020). https://doi.org/10.1016/j.promfg.2020.10.117CrossRef

22.

Dolan, J.A.: Forensic Analysis of Fire Debris, 2nd edn. Elsevier, Amsterdam (2007)

23.

NPL: National physical laboratory. Kaye Laby Tables Phys. Chem. Constants 1, 1–11 (2017)

24.

Expansion, T: Thermal properties of metals, conductivity, thermal expansion. Specific Heat, 1–5 (2017)

25.

Sanchez, J.A.; Pombo, I.; Cabanes, I.; Ortiz, R.; de Lacalle, L.N.L.: Electrical discharge truing of metal-bonded CBN wheels using single-point electrode. Int. J. Mach. Tools. Manuf. 48, 362–370 (2008). https://doi.org/10.1016/j.ijmachtools.2007.10.002CrossRef

26.

Chakraborty, S.; Dey, V.; Ghosh, S.K.: A review on the use of dielectric fluids and their effects in electrical discharge machining characteristics. Precis. Eng. 40, 1–6 (2015). https://doi.org/10.1016/j.precisioneng.2014.11.003CrossRef

27.

Mandaloi, G.; Singh, S.; Kumar, P.; Pal, K.: Effect on crystalline structure of AISI M2 steel using tungsten-thorium electrode through MRR, EWR, and surface finish. Meas. J. Int. Meas. Confed. 90, 74–84 (2016). https://doi.org/10.1016/j.measurement.2016.04.041CrossRef

28.

Tzeng, Y.F.; Lee, C.Y.: Effects of powder characteristics on electrodischarge machining efficiency. Int. J. Adv. Manuf. Technol. 17, 586–592 (2001). https://doi.org/10.1007/s001700170142CrossRef

29.

Dong, H.; Liu, Y.; Li, M.; Zhou, Y.; Liu, T.; Li, D., et al.: Experimental investigation of water-in-oil nanoemulsion in sinking electrical discharge machining. Mater. Manuf. Process. 34, 1129–1135 (2019). https://doi.org/10.1080/10426914.2019.1628266CrossRef

30.

Plaza, S.; Ortega, N.; Sanchez, J.A.; Pombo, I.; Mendikute, A.: Original models for the prediction of angular error in wire-EDM taper-cutting. Int. J. Adv. Manuf. Technol. 44, 529–538 (2009). https://doi.org/10.1007/s00170-008-1842-5CrossRef

31.

Adachi, Y.; Yoshida, M.; Kunieda, M.: Study on process reaction force caused by bubble formation in EDM. Study Process React Force Caused Bubble Form EDM 31, 23–30 (1997). https://doi.org/10.2526/jseme.31.67_23CrossRef

32.

Pellegrini, G.; Ravasio, C.: Evaluation of the sustainability of the micro-electrical discharge milling process. Adv. Prod. Eng. Manag. 14(3), 343–354 (2019)

33.

Leão, F.N.; Pashby, I.R.: A review on the use of environmentally-friendly dielectric fluids in electrical discharge machining. J. Mater. Process. Technol. 149, 341–346 (2004)CrossRef

34.

Chen, S.; Lin, M.; Huang, G.; Wang, C.: Research of the recast layer on implant surface modified by micro-current electrical discharge machining using deionized water mixed with titanium powder as dielectric solvent. Appl Surf Sci 311, 47–53 (2014). https://doi.org/10.1016/j.apsusc.2014.04.204CrossRef

35.

Kumar, A.; Mandal, A.; Dixit, A. R.; Das, A. K.: Performance evaluation of Al₂O₃ nano powder mixed dielectric for electric discharge machining of inconel 825. Mater. Manuf. Process. ISSN: 1042-6914 (Print) 1532–2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

36.

Theisen, W.; Schuermann, A.: Electro discharge machining of nickel-titanium shape memory alloys. Mater. Sci. Eng. A 378, 200–204 (2004). https://doi.org/10.1016/j.msea.2003.09.115CrossRef

37.

Singh, B.; Kumar, J.; Kumar, S.: Experimental investigation on surface characteristics in powder-mixed electrodischarge machining of AA6061/10%SiC composite. Mater. Manuf. Process. 29, 287–297 (2014). https://doi.org/10.1080/10426914.2014.880463CrossRef

38.

Lee, S.H.; Li, X.: Study of the surface integrity of the machined workpiece in the EDM of tungsten carbide. J. Mater. Process. Technol. 139, 315–321 (2003). https://doi.org/10.1016/S0924-0136(03)00547-8CrossRef

39.

Singh, J.; Singh, G.; Pandey, P.M.: Electric discharge machining using rapid manufactured complex shape copper electrode with cryogenic cooling channel. Proc. Instit. Mech. Eng. Part B J. Eng. Manuf. 235(1–2), 173–185 (2021)CrossRef

40.

Sanchez, J.A.; Ortega, N.; De Lacalle, L.N.L.; Lamikiz, A.; Marañon, J.A.: Analysis of the electro discharge dressing (EDD) process of large-grit size cBN grinding wheels. Int. J. Adv. Manuf. Technol. 29, 688–694 (2006). https://doi.org/10.1007/s00170-005-2579-zCrossRef

41.

Hasçalik, A.; Çaydaş, U.: Electrical discharge machining of titanium alloy (Ti-6Al-4V). Appl. Surf. Sci. 253, 9007–9016 (2007). https://doi.org/10.1016/j.apsusc.2007.05.031CrossRef

42.

Reddy, V.V.; Kumar, A.; Valli, P.M.; Reddy, C.S.: Influence of surfactant and graphite powder concentration on electrical discharge machining of PH17-4 stainless steel. J. Braz. Soc. Mech. Sci. Eng. 37, 641–655 (2015). https://doi.org/10.1007/s40430-014-0193-4CrossRef

43.

Li, C.P.; Kim, M.Y.; Islam, M.M.; Ko, T.J.: Mechanism analysis of hybrid machining process comprising EDM and end milling. J. Mater. Process. Technol. 237, 309–319 (2016). https://doi.org/10.1016/j.jmatprotec.2016.06.022CrossRef

44.

Ekmekci, B.; Elkoca, O.; Tekkaya, A.E.; Erden, A.: Residual stress state and hardness depth in electric discharge machining: de-ionized water as dielectric liquid. Mach. Sci. Technol. 9, 39–61 (2005). https://doi.org/10.1081/MST-200051244CrossRef

45.

Vinoth Kumar, S.; Pradeep, K.M.: Machining process parameter and surface integrity in conventional EDM and cryogenic EDM of Al–SiCp MMC. J. Manuf. Process. 20, 70–78 (2015). https://doi.org/10.1016/j.jmapro.2015.07.007CrossRef

46.

Ming, W.; Xie, Z.; Cao, C.; Liu, M.; Zhang, F.; Yang, Y.; Zhang, S.; Sun, P.; Guo, X.: Research on EDM performance of renewable dielectrics under different electrodes for machining SKD11. Crystals 12, 291 (2022). https://doi.org/10.3390/cryst12020291CrossRef

47.

Lin, Y.C.; Chen, Y.F.; Lin, C.T.; Tzeng, H.J.: Electrical discharge machining (EDM) characteristics associated with electrical discharge energy on machining of cemented tungsten carbide. Mater. Manuf. Process. 23, 391–399 (2008). https://doi.org/10.1080/10426910801938577CrossRef

48.

Prabhu, S.; Vinayagam, B.K.: Analysis of surface characteristics of AISI D2 tool steel material using electric discharge machining process with single wall carbon nano tubes. Int. J. Eng. Technol. 2, 35–41 (2014). https://doi.org/10.7763/ijet.2010.v2.96CrossRef

49.

Singh, J.; Singh, G.; Pandey, P.M.: Electric discharge machining using rapid manufactured complex shape copper electrode: parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions. Proc. Inst. Mech. Eng. C J. Mech. Eng. Sci. 234(12), 2459–2473 (2020)CrossRef

50.

Yadav, R.N.: Electro-chemical spark machining-based hybrid machining processes: research trends and opportunities. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. (2018). https://doi.org/10.1177/0954405418755825CrossRef

51.

Dhakara, K.; Dvivedia, A.: Parametric evaluation on near-dry electric discharge, machining. Mater. Manuf. Process. Mater. Manuf. Process. 26 July 2015, At: 23:49.

52.

Singh, S.; Bhardwaj, A.: Review to EDM by using water and powder-mixed dielectric fluid. J. Miner. Mater. Charact. Eng. 10(2), 199–230 (2011)

53.

Nguyen, M.D.; Rahman, M.; Wong, Y.S.: An experimental study on micro-EDM in low-resistivity deionized water using short voltage pulses. Int. J. Adv. Manuf. Technol. 58, 533–544 (2012). https://doi.org/10.1007/s00170-011-3397-0CrossRef

54.

Sharma, A.; Kumar, V.; Babbar, A.; Dhawan, V.; Kotecha, K.; Prakash, C.: Experimental investigation and optimization of electric discharge machining process parameters using grey-fuzzy-based hybrid techniques. Materials 14, 5820 (2021). https://doi.org/10.3390/ma14195820CrossRef

55.

Kumar, S.: Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric. J. Manuf. Process. 14, 35–40 (2012). https://doi.org/10.1016/j.jmapro.2011.09.002CrossRef

56.

Chaudhari, R.; Vora, J.J.; Mani Prabu, S.S.; Palani, I.A.; Patel, V.K.; Parikh, D.M.; de Lacalle, L.N.L.: Multi-response optimization of WEDM process parameters for machining of superelastic nitinol shape-memory alloy using a heat-transfer search algorithm. Mater. 12(8), 1277 (2019).CrossRef

57.

Gadalla, A.M.; Bozkurt, B.: Expanding heat source model for thermal spalling of TiB₂ in electrical discharge machining. J. Mater. Res. 7, 2853–2858 (1992). https://doi.org/10.1557/JMR.1992.2853CrossRef

58.

Ishfaq, K.; Maqsood, M.; Mahmood, M.: Machining characteristics of various powder-based additives, dielectrics, and electrodes during EDM of micro-impressions: a comparative study. Int. J. Adv. Manuf. Technol. 123, 1521–1541 (2022). https://doi.org/10.1007/s00170-022-10254-8CrossRef

59.

Wang, C.; Qiang, Z.: Comparison of micro-EDM characteristics of inconel 706 between EDM oil and an Al powder-mixed dielectric. Adv. Mater. Sci. Eng. (2019). https://doi.org/10.1155/2019/5625360CrossRef

60.

Chandrashekarappa, M.P.G.; Kumar, S.; Jagadish, J.; Pimenov, D.Y.; Giasin, K.: Experimental analysis and optimization of EDM parameters on HcHcr steel in context with different electrodes and dielectric fluids using hybrid taguchi-based PCA-utility and CRITIC-utility approaches. Metals 11, 419 (2021). https://doi.org/10.3390/met11030419CrossRef

Titel: An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance
verfasst von: Kamlesh Paswan
Alokesh Pramanik
Somnath Chattopadhyaya
Shubham Sharma
Gurminder Singh
Aqib Mashood Khan
Sunpreet Singh
Publikationsdatum: 03.02.2023
Verlag: Springer Berlin Heidelberg
Erschienen in: Arabian Journal for Science and Engineering / Ausgabe 9/2023
Print ISSN: 2193-567X
Elektronische ISSN: 2191-4281
DOI: https://doi.org/10.1007/s13369-023-07626-x

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht

Springer Professional

Abstract

Bitte loggen Sie sich ein, um Zugang zu Ihrer Lizenz zu erhalten.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Weitere Artikel der Ausgabe 9/2023

Numerical and Analytical Investigation of the Surface Evaporation Rate of the Different Nanofluids and Optimization Results by Using the RSM Method

Optimization of Cutting Parameters and Result Predictions with Response Surface Methodology, Individual and Ensemble Machine Learning Algorithms in End Milling of AISI 321

Dual Characteristics of Maxwell Hybrid Nanofluid Flow Over a Shrinking Sheet with Variable Heat Source or Sink

Decentralized Robust Control of Robotic Manipulator in Joint Space Based on Torque Feedbacks

Improving the Cooling Performance in a Low Reynolds Duct Flow of Multiple Impinging Jets with Non-uniform Spacing and Unequal Diameters of Nozzles

Ultra-Low-Frequency Broadband Sound Absorption Characteristics of an Acoustic Metasurface with Pie-Sliced Unit Cells

Premium Partner

Marktübersichten