Statistical Description of Debris Particle Size Distribution in Electrical Discharge Machining

Gap debris as discharge product is closely related to machining process in electrical discharge machining（EDM）. A lot of recent researches have focused on the relationship among debris size, surfaces texture, remove rate, and machining stability. The study on statistical distribution of debris size contributes to the research, but it is still superficial currently. In order to obtain the distribution law of the debris particle size, laser particle size analyzer（LPSA） combined with scanning electron microscope（SEM） is used to analyze the EDM debris size. Firstly, the heating dried method is applied to obtain the debris particles. Secondly, the measuring range of LPSA is determined as 0.5–100 μm by SEM observation, and the frequency distribution histogram and the cumulative frequency distribution scattergram of debris size are obtained by using LPSA. Thirdly, according to the distribution characteristic of the frequency distribution histogram, the statistical distribution functions of lognormal, exponentially modified Gaussian（EMG）, Gamma and Weibull are chosen to achieve curve fitting of the histogram. At last, the distribute law of the debris size is obtained by fitting results. Experiments with different discharge parameters are carried out on an EDM machine designed by the authors themselves, and the machining conditions are tool electrode of red-copper material, workpiece of ANSI 1045 material and working fluid of de-ionized water. The experimental results indicate that the debris sizes of all experiment sample truly obey the Weibull distribution. The obtained distribution law is significantly important for all the models established based on the debris particle size.

Micro Electrical Discharge Machining Deposition in Air for Fabrication of Micro Spiral Structures

Micro electrical discharge machining（EDM） deposition process is a new micro machining method for fabrication of metal micro structures. In this process, the high level of tool electrode wear is used to achieve the metal material deposition. Up to now, the studies of micro EDM deposition process focused mainly on the researches of deposition process, namely the effects of discharge parameters in deposition process on the deposition rate or deposition quality. The research of the formation of micro structures with different discharge energy density still lacks. With proper conditions and only by the z-axis feeding in vertical direction, a novel shape of micro spiral structure can be deposited, with 0.11 mm in wire diameter, 0.20 mm in outside diameter, and 3.78 mm in height. Then some new deposition strategies including angular deposition and against the gravity deposition were also successful. In order to find the forming mechanism of the spiral structures, the numerical simulation of the transient temperature distribution on the discharge point was conducted by using the finite-element method（FEM）. The results show that there are two major factors lead to the forming of the spiral structures. One is the different material removal form of tool electrode according with the discharge energy density, the other is the influenced degree of the movement of the removed material particles in the discharge gap. The more the energy density in single discharge is, the smaller the mass of the removed material particles is, and the easier the movements of which will be changed to form an order tendency. The fine texture characteristics of the deposited micro spiral structures were analyzed by the energy spectrum analysis and the metallographic analysis. It shows that the components of the deposited material are almost the same as those of the tool electrode. Moreover the deposited material has the brass metallic luster in the longitudinal profile and has compact bonding with the base material. This research is useful to understand the micro-process of micro EDM deposition better and helpful to increase the controllability of the new EDM method for fabrication of micro structures.

Surface Modification Process by Electrical Discharge Machining with Ti Powder Green Compact Electrode

This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.

Experimental Research on Effects of Process Parameters on Servo Scanning 3D Micro Electrical Discharge Machining

Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm×600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.

Micro electrical discharge machining of small hole in TC4 alloy

Aiming at machining deeply small holes in TC4 alloy,a series of experiments were carried out on a self-developed multi-axis micro electrical discharge machining(micro-EDM)machine tool.To improve machining efficiency and decrease relative wear of electrode in machining deeply small hole in TC4 alloy,many factors in micro-EDM,such as polarity,electrical parameters and supplying ways of working fluid were studied.Experimental results show that positive polarity machining is far superior to negative polarity machining;it is more optimal when open-circuit voltage,pulse width and pulse interval are 130 V,5μs and 15μs respectively on the self developed multi-axis micro-EDM machine tool;when flushing method is applied in micro-EDM,the machining efficiency is higher and relative wear of electrode is smaller.

MICRO ELECTRICAL DISCHARGE MACHINING DEPOSITION IN AIR

A new deposition method is described using micro electrical discharge machining （EDM） to deposit tool electrode material on workpiece in air. The basic principles of micro electrical discharge deposition （EDD） are analyzed and the realized conditions are predicted. With an ordinary EDM shaping machine, brass as the electrode, high-speed steel as the workpiece, a lot of experiments are carried out on micro EDD systematically and thoroughly. The effects of major processing parameters, such as the discharge current, discharge duration, pulse interval and working medium, are obtained, As a result, a micro cylinder with 0.19 mm in diameter and 7.35 mm in height is deposited. By exchanging the polarities of the electrode and workpiece the micro cylinder can be removed selectively. So the reversible machining of deposition and removal is achieved, which breaks through the constraint of traditional EDM. Measurements show that the deposited material is compact and close to workpiece base, whose components depend on the tool electrode, material.

Scale Effects and a Method for Similarity Evaluation in Micro Electrical Discharge Machining

Electrical discharge machining（EDM） is a promising non-traditional micro machining technology that offers a vast array of applications in the manufacturing industry. However, scale effects occur when machining at the micro-scale, which can make it difficult to predict and optimize the machining performances of micro EDM. A new concept of ＂scale effects＂ in micro EDM is proposed, the scale effects can reveal the difference in machining performances between micro EDM and conventional macro EDM. Similarity theory is presented to evaluate the scale effects in micro EDM. Single factor experiments are conducted and the experimental results are analyzed by discussing the similarity difference and similarity precision. The results show that the output results of scale effects in micro EDM do not change linearly with discharge parameters. The values of similarity precision of machining time significantly increase when scaling-down the capacitance or open-circuit voltage. It is indicated that the lower the scale of the discharge parameter, the greater the deviation of non-geometrical similarity degree over geometrical similarity degree, which means that the micro EDM system with lower discharge energy experiences more scale effects. The largest similarity difference is 5.34 while the largest similarity precision can be as high as 114.03. It is suggested that the similarity precision is more effective in reflecting the scale effects and their fluctuation than similarity difference. Consequently, similarity theory is suitable for evaluating the scale effects in micro EDM. This proposed research offers engineering values for optimizing the machining parameters and improving the machining performances of micro EDM.

Modelling effect of magnetic field on material removal in dry electrical discharge machining

One of the reasons for increased material removal rate in magnetic field assisted dry electrical discharge machining （EDM） is confinement of plasma due to Lorentz forces. This paper presents a mathematical model to evaluate the effect of external magnetic field on crater depth and diameter in single- and multiple-discharge EDM process. The model incorporates three main effects of the magnetic field, which include plasma confinement, mean free path reduction and pulsating magnetic field effects. Upon the application of an external magnetic field, Lorentz forces that are developed across the plasma column confine the plasma column. Also, the magnetic field reduces the mean free path of electrons due to an increase in the plasma pressure and cycloidal path taken by the electrons between the electrodes. As the mean free path of electrons reduces, more ionization occurs in plasma column and eventually an increase in the current density at the inter-electrode gap occurs. The model results for crater depth and its diameter in single discharge dry EDM process show an error of 9%-10% over the respective experimental values.

Trajectory optimisation in electrical discharge machining of three-dimensional curved and twisted channels

Numerical control electrical discharge machining(NC EDM) is one of the most widely used machining technologies for manufacturing a closed blisk flow path, particularly for three-dimensional(3D) curved and twisted flow channels. In this process, tool electrode design and machining trajectory planning are the key factors affecting machining accessibility and efficiency. Herein, to reduce the difficulty in designing the electrode and its motion path in the closed curved and twisted channels, a heuristic search hybrid optimisation strategy based on channel grids is adopted to realise the initial electrode trajectory design search and optimised size reduction. By transferring the trajectory optimisation constraints from the complex free-form surface to numbered grids, the search is found to be more orderly and accurate. The two trajectory indicators, namely argument angle and minimum distance, are analysed separately for the optimised results of the adaptive learning particle swarm optimisation algorithm, demonstrating that they can meet the actual processing requirements.Experimental results of NC EDM indicate that the motion path generated by this design method can meet the machining requirements of 3D curved and twisted flow channels.

Electrical Discharge Machining of Al2024-65 vol%SiC Composites

In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness（Ra）, X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy（TEM） techniques. Three zones from the surface to the interior（melting zone, heat affected zone and un-affected zone） were found in the machined composites, while the face of SiC particles on the surface toward the outside was ‘‘cut＇＇ to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024 Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.

Simulation of Adaptive Control Strategy for Electrical Discharge Machining Process

Electrode down-time is an important factor affecting the efficiency and stability of electrical discharge machining(EDM) process. In the research, a way of simulating the regulation of the electrode down-time in an EDM adaptive control system has been studied. All the simulations are performed on Matlab. The simulation results demonstrate that this adaptive controller by regulating electrode down-time can direct the gap state to follow the specified reference gap state with or without disturbances. Finally, the adaptive control scheme is also validated by experiments. The significance of the simulation of an EDM adaptive control system lies on the fact that it provides a convenient way to guide the actual production and provides a new study method for the research of EDM control strategy with no regard of experimental conditions.

Optimization algorithms and intelligent techniques on electrical discharge machining process

Electrical Discharge Machining (EDM) is considered as the much traditional, adaptableand unconventional machining process that is proficient in generating complicated structures. Further, it is self-sufficient over the mechanical properties of workpiece materialsonly if it is conductive. The viability of the EDM process regarding the application typesmight get considerably improved with the constant enhancement in the personificationof numerical control and the metal removal efficacy. This survey intends to make a reviewof 65 papers related to the optimization and modeling of EDM process machining. Theanalysis is thus made with regards to the following factors like Al alloy composite in DieShrinking EDM, Optimization and Al metal matrix composites. Particularly, the hybridoptimization models in various papers are analyzed concerning their logic. Further, thealgorithmic and parametric analysis is also made with the contributed papers. Finally,the research gaps and challenges in this EDM processing are discussed, which wouldpave the way for efficient research works in this area.

Electrical discharge and arc milling with automatic tracking of optimal flushing direction:A novel high-efficiency compound machining method

The arc milling method has the advantages of high machining efficiency and low cost and is independent of the strength and hardness of machined materials.However,frequent electrode back-offs and the risk of workpiece burning may occur if erosion products are not removed promptly.In this study,it was found that the flushing method of the working medium had a significant impact on the machining performance of arc milling.Based on this,a novel highefficiency compound machining method of electrical discharge and arc milling with automatic tracking of the optimal flushing direction was proposed.An automatic tracking optimizer for external working medium injection was designed to determine the optimal external flushing direction according to the feed direction.The influence of flushing methods,working mediums,and machining parameters on the machining efficiency,tool electrode wear rate,machining error,and surface integrity of titanium alloys were investigated.The results indicated that better machining performance and environmental friendliness were achieved using the compound flushing method of outer compressed air and inner deionized water.Additionally,the automatic tracking flushing method in the opposite direction of the feed direction showed superior results compared to other directions.The material removal rate with the opposite direction injection could be increased up to 1.62 times that of the same direction,and the relative electrode wear rate could be reduced by 14.76%.This novel method has broad application prospects for machining parts with difficult-to-cut materials in aerospace and military industries.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Influence of Input Factors on Surface Roughness and Material Removal Speed when Wire-EDM a Hardened SKD11 Steel Curve Profile

The goal of this research is to identify the best set of process machining parameters for wire-EDM(Electrical Discharge Machining)cutting of hardened SKD11 steel when machining a curve profile.The multi-objective function includes reducing surface roughness and increasing MRR(Material Removal Rate).The optimization process is prepared by using Taguchi method coupled Grey Relational Analysis.The obtained results revealed that Toff has the greatest influence on the average grey value(48.30%),followed by the influence of WF(Wire Feed,15.99%),VM(Cutting Voltage,9.33%),SV(Server Voltage,5.05%),Ton(Pulse on Time,1.81%),while SPD(Cutting Speed)has a negligible effect(0.89%).Moreover,using the optimal set of machining parameters generates in surface roughness of 1.25399mm and MRR of 26.5562 mm^(2)/min.The verification experiment and Anderson-Darling method demonstrate the validity of the proposed model,which can be utilized for estimating surface roughness and MRR.

Finite element modeling and analysis of powder mixed electric discharge machining process for temperature distribution and volume removal considering multiple craters

Powder mixed electric discharge machining(PMEDM)is one of the modern developments in electric discharge machining(EDM)process.In the present work,finite element modeling has been carried out considering randomly oriented multiple sparks during PMEDM.Transient thermal analysis is done to obtain temperature distribution,volume removal,and proportion of volume removed by melting and evaporation at different current,pulse on time and fraction of heat that enters to work piece.Gradually growing spark behavior and Gaussian distribution of heat source is used to simulate multiple craters.Temperature distribution along radial direction shows peak temperature at center of spark and thereafter a gradual decrease with increase in radial distance.Along depth direction temperature sharply decreases that forms wider craters with shallow depth in PMEDM.Peak temperature and volume removal increases with current more rapidly.Volume removal by melting is much higher than evaporation at lower current settings and with higher current almost equal amount of material is removed by melting and evaporation thus reducing the re-solidification of melted material.Current plays a significant role behind the contribution of material removal by evaporation followed by fraction of heat.Increase in pulse on duration increases the total volume of material removal however does not significantly increase the proportion of volume removal by vaporization.

Surface-improvement mechanism of hybrid electrochemical discharge process using variable-amplitude pulses

Superalloys are commonly used in aircraft manufacturing;however,the requirements for high surface quality and machining accuracy make them difficult to machine.In this study,a hybrid electrochemical discharge process using variable-amplitude pulses is proposed to achieve this target.In this method,electrochemical machining(ECM)and electrical discharge machining(EDM)are unified into a single process using a sequence of variable-amplitude pulses such that the machining process realizes both good surface finish and high machining accuracy.Furthermore,the machining mechanism of the hybrid electrochemical discharge process using variable-amplitude pulses is studied.The mechanism is investigated by observations of machining waveforms and machined surface.It is found that,with a high-frequency transformation between high-and low-voltage waveforms within a voltage cycle,the machining mechanism is frequently transformed from EDM to pure ECM.The critical discharge voltage is 40 V.When pulse voltages greater than 40 V are applied,the machining accuracy is good;however,the surface has defects such as numerous discharge craters.High machining accuracy is maintained when high-voltage pulses are replaced by low-voltage pulses to enhance electrochemical dissolution.The results indicate that the proposed hybrid electrochemical discharge process using variable-amplitude pulses can yield high-quality surfaces with high machining accuracy.

Analysis and optimization of sustainable machining of AISI O1 tool steel by the wire-EDM process

Wire electrical discharge machining(wire-EDM)is an energy-intensive process,and its success relies on a correct selection of cutting parameters.It is vital to optimize energy consumption,along with productivity and quality.This experimental study optimized three parameters in wire-EDM:pulse-on time,servo voltage,and voltage concerning machining time,electric power,total energy consumption,surface roughness,and material removal rate.Two different plate thicknesses(15.88 mm and 25.4 mm)were machined.An orthogonal array,signal-to-noise ratio,and means graphs,and an analysis of vari-ance(ANOVA),determine the effects and contribution of cutting parameters on responses.Pulse-on time is the most significant factor for almost all variables,with a percentage of contribution higher than 50%.Multi-objective optimization is conducted to accomplish a concurrent decrease in all variables.A case study is proposed to compute carbon dioxide(CO_(2))tons and electricity cost in wire-EDM,using cutting parameters from multi-objective optimization and starting values commonly employed to cut that tool steel.A sustainable manufacturing approach reduced 5.91%of the electricity cost and CO_(2)tons when machining the thin plate,and these responses were diminished by 14.09%for the thicker plate.Therefore,it is possible to enhance the sustainability of the process without decreasing its productivity and quality.

Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

Machining of shape memory alloys(SMAs)without losing the shape memory effect could immensely extend their applications.Herein,the wire electric discharge machining process was used to machine NiTi—a shape memory alloy.The experimental methodology was designed using a Box-Behnken design approach of the response surface methodology.The effects of input variables including pulse on time,pulse off time,and current were investigated on the material removal rate,surface roughness,and microhardness.ANOVA tests were performed to check the robustness of the generated empirical models.Optimization of the process parameters was performed using a newly formulated,highly efficient heat transfer search algorithm.Validation tests were conducted and extended for analyzing the retention of the shape memory effect of the machined surface by differential scanning calorimetry.In addition,2D and 3D Pareto curves were generated that indicated the trade-offs between the selected output variables during the simultaneous output variables using the multi-objective heat transfer search algorithm.The optimization route yielded encouraging results.Single objective optimization yielded a maximum material removal rate of 1.49 mm^(3)/s,maximum microhardness 462.52 HVN,and minimum surface roughness 0.11μm.The Pareto curves showed conflicting effects during the wire electric discharge machining of the shape memory alloy and presented a set of optimal non-dominant solutions.The shape memory alloy machined using the optimized process parameters even indicated a shape memory effect similar to that of the starting base material.

Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method

Fast drilling electrical discharge machining(EDM)is widely used in the manufacture of film cooling holes of turbine blades.However,due to the various hole orientations and severe electrode wear,it is relatively intricate to accurately and timely identify the critical moments such as breakout,hole completion in the drilling process,and adjust the machining strategy properly.Existing breakout detection and hole completion determination methods are not suitable for the high-efficiency and fully automatic production of film cooling holes,for they almost all depend on preset thresholds or training data and become less appropriate when machining condition changes.As the breakout and hole completion detection problems can be abstracted to an online stage identification problem,in this paper,a kurtosis-based stage identification(KBSI)method,which uses a novel normalized kurtosis to denote the recent changing trends of gap voltage signals,is developed for online stage identification.The identification accuracy and generalization ability of the KBSI method have been verified in various machining conditions.To improve the overall machining efficiency,the influence of servo control parameters on machining efficiency of each machining stage was analyzed experimentally,and a new stage-wise adaptive control strategy was then proposed to dynamically adjust the servo control parameters according to the online identification results.The performance of the new strategy is evaluated by drilling film cooling holes at different hole orientations.Experimental results show that with the new control strategy,machining efficiency and the machining quality can be significantly improved.