Review on recent development in environmental-friendly EDM techniques

• Autorzy: Singh N. K. , Singh K. K.

Identyfikatory

DOI

10.2478/amst-2015-0002

Warianty tytułu

PL

Rozwój zaawansowanych i ekologicznych metod cięcia elektroerozyjnego EDM

• Języki publikacji: EN

Abstrakty

EN

The electrical discharge machining (EDM) is unitary of the widely used unconventional machining because of its ability to cut very hard material engendering high dimensional accuracy as well. In thermo-electric process, control sparks generation between electrodes causes material removal; however, application of hydrocarbon oil based dielectric is an issuance of environmental disruption. To rectify this problem, replacement of dielectric is main concerns in EDM research. This paper highlights Dry-EDM, Near-Dry EDM and EDM in water, which is conceived as an environment amiable alteration in the oil EDM process. The work gives a thorough review of Dry, near-dry EDM and EDM in water as a process, where the target is to endeavor dielectric fluids that can be substituted bypassing hydrocarbon oil. It is perceived that water and gas based dielectrics could take over oil-based fluids in die sink applications. Novel technological advances in dry EDM machining processes, which deliberate the relatively advanced stage of a technology in to the area of academic and industrial research is briefly reviewed. An outline of the prospective trend of reviewing is intimate in the last fragment.

PL

Proces cięcia elektroerozyjnego (EDM) jest stosowany w obróbce materiałów o dużej twardości. Umożliwia przecinanie elementów o złożonym kształcie. Materiał w procesie EDM jest usuwany w wyniku jego erozji spowodowanej wyładowaniami elektrycznymi pomiędzy elektrodą roboczą i przedmiotem obrabianym zanurzonym w ciekłym dielektryku – oleju węglowodorowym. Czynnik izolujący jest częstą przyczyną nagłego przerywania procesu cięcia. Stąd konieczność prowadzenia badań dla opracowanych dielektryków umożliwiających prowadzenie procesu w sposób ciągły. W pracy przedstawiono ogólną charakterystykę procesu EDM poddanego modyfikacji. Olej węglowodorowy zastąpiono lub całkowicie usunięto z procesu cięcia. Scharakteryzowano proces cięcia elektroerozyjnego na sucho (Dry-EDM), proces zbliżony do suchego (Near-Dry EDM) i proces cięcia w wodzie. Przewiduje się, że zastąpienie oleju wodą lub gazami cechującymi się dobrymi właściwościami dielektrycznymi umożliwi uzyskanie parametrów procesu cięcia zapewniających bezawaryjną i ciągłą pracę urządzenia EDM. Przedstawiono zaawansowaną metodę cięcia elektroerozyjnego, bez konieczności stosowania czynnika ciekłego. Jest to metoda przyjazna dla środowiska, obecnie opracowywana w wielu instytutach badawczych dla zastosowania w praktyce przemysłowej.

Słowa kluczowe

EN

electro-discharge machining; EDM; Dry-EDM; Near-dry EDM

PL

proces cięcia elektroerozyjnego; EDM; proces suchy EDM; proces półsuchy EDM

• Wydawca: Komitet Budowy Maszyn PAN ; De Gruyter
• Czasopismo: Advances in Manufacturing Science and Technology
• Rocznik: 2015
• Tom: Vol. 39, nr 1
• Strony: 17--37
• Opis fizyczny: Bibliogr. 72 poz., fot., rys.

Twórcy

autor

Singh N. K.

• Mechanical Engineering Department, Hindustan College of Science and Technology, Agra-Delhi Highway (NH-2), Farah, Distt. Mathura-281122, India

autor

Singh K. K.

• Mechanical Engineering Department, Hindustan College of Science and Technology, Agra-Delhi Highway (NH-2), Farah, Distt. Mathura-281122, India

Bibliografia

• [1] K.H. HO, S.T. NEWMAN: State of the art electrical discharge machining (EDM). Int. Journal of Machine Tools & Manufacture, 43(2003), 1287-1300.
• [2] S. KUMAR et al.: Electric discharge machining of titanium and its alloys: a review. Int. Journal of Machining and Machinability of Materials, (2012).
• [3] N.M. ABBAS, D.G. SOLOMON, M.F. BAHARI: A review on current research trends in electrical discharge machining (EDM). Int. Journal of Machine Tools & Manufacture, 47(2007), 1214-1228.
• [4] S.M. PANDIT, K.P. RAJURKAR: Analysis of electro discharge machining of cemented carbides. Annals of the CIRP, 30(1981)1, 111-116.
• [5] M.H. LI: The theoretical bases of electrical discharge machining. Defense Industry Press, Beijing 1989.
• [6] S. HOH: Mechanism of EDM. Proc. JSPE, Tokyo 1963.
• [7] W. KONIG, F.J. SIEBERS: Influence of the working medium on the removal process in EDM sinking. ASME PED, 64(1993), 649-656.
• [8] P.K. ECKMAN, E.M. WILLIAMS: Plasma dynamics in an arc formed by lowvoltage sparkover of a liquid dielectric. Applied Scientific Research, 6(1960)8, 299-320.
• [9] S.N. ZOLOTYKH: The Mechanism of electrical erosion of metals in liquid dielectric media. Soviet Phys. Tech. Phys., 4(1959)12, 1370-1373.
• [10] F. HAN, M. KUNIEDA: Development of parallel spark electrical discharge machining. Precision Engineering, 28(2004), 65-72.
• [11] F.N. LEAO, I.R. PASHBY: A review on the use on environmentally-friendly dielectric fluids in electrical discharge machining. Journal of Material Processing Technology, 149(2004(1-3), 341-346.
• [12] I. BESLIU et al.: Study of dry electrical discharge machining. Int. Journal of Material Forming, 3(2010)1, 1107-1110.
• [13] V. RAMANI, M.L. CASSIDENTI: Inert-gas electrical-discharge machining. NASA Technical Brief No. NPO-15660. 1985.
• [14] M. KUINEDA et al.: Improvement of EDM efficiency by supplying oxygen gas. CIRP Annals- Manufacturing Technology, 40(1991), 215-218.
• [15] M. KUINEDA, M. YOSHIDA: Electrical discharge machining in gas. CIRP Annals- Manufacturing Technology, 46(1997), 143-146.
• [16] G. SKRABALAK, J. KOZAK: Study on dry electrical discharge machining. Proc. of the World Congress on Engineering, Vol. III, WCE London 2010.
• [17] I. BESLIU, M. COTEATA: Characteristics of the dry electrical discharge machining. Nonconventional Technologies Review, (2009)2.
• [18] M. YOSHIDA, M. KUNIEDA: Study on mechanism for minute tool electrode wear in dry EDM. Seimitsu Kogaku Kaishi/Journal of the Japan Society for Precision Engineering, 65(1999), 689-693.
• [19] Y. ZHANBO, J. TAKAHASHI, N. NAKAJIMA, S. SANO, K. KARATO, M. KUNIEDA: Feasibility of 3-D surface machining by dry EDM. Int. Journal of Electrical Machining, 10(2005), 15-20.
• [20] H. YU et al.: Dry electrical discharge machining of cemented carbide. 14th Int. Symposium on Electro machining (ISMEXIV). Journal of Material Processing Technology, 149(2004), 353-357.
• [21] Q.H. ZHANG, J.H. ZHANG, J.X. DENG, Z.W. NIU: Ultrasonic vibration in electrical discharge machining in gas. Journal of Materials Process and Technology, 129(2002), 135-138.
• [22] Q.H. ZHANG, J.H. Zhang, Q.B Zhang: An Investigation of ultrasonic–assisted electrical discharge machining in gas. Int. Journal of Machine Tools & Manufacture, 46(2006), 1582-1588.
• [23] S.K. SAHA, S.K. CHOUDHURY: Experimental investigation and empirical modeling of the dry electric discharge machining process. Int. Journal of Machine Tools and Manufacture, 49(2009), 297-308.
• [24] H. XU et al.: Material removal mechanisms of cemented carbides machined by ultrasonic vibration assisted EDM in gas medium. Journal of Materials Processing Technology, (2009), 1742-1746.
• [25] P. GOVINDAN, S. JOSHI: Investigations into Performance of Dry EDM Using Slotted Electrodes. Int. Journal of Precision Engineering and Manufacturing, 12(2011)6, 957-963.
• [26] M. KUNIEDA, T. TAKAYA, S. NAKANO: Improvement of dry EDM characteristics using piezoelectric actuator. CIRP Annals-Manufacturing Technology, 53(2004), 183-186.
• [27] R. ROTH et al.: Influence of oxidizing gas on the stability of dry electrical discharge machining process. Procedia CIRP, 6(2013), 339-344.
• [28] R. ROTH et al.: Influence of the anode material on the breakdown behavior in dry electrical discharge machining. Procedia CIRP, 1(2012), 639-644.
• [29] P. GOVINDAN et al.: Experimental characterization of material removal in dry electrical discharge drilling, Int. Journal of Machine Tools & Manufacture, 50(2010), 431-443.
• [30] L. LI et al.: Discussion of electrical discharge machining in gas. Proc. the 31st IEEE Int. Conference on Plasma Science, ICOPS 2004. IEEE Conference Record, 2004.
• [31] L.Q. ZHANG et al.: Discussion of electrical discharge machining in gas. Proc. the 31st IEEE International Conference on Plasma Science, ICOPS 2004. IEEE Conference Record, 2004.
• [32] A. CURODEAU, M. RICHARD, L. FROHN-VILLENEUVE: Molds surface finishing with new EDM process in air with thermoplastic composite electrodes. Journal of Materials Processing Technology, 149(2004), 278-283.
• [33] S. JOSHI et al.: Experimental characterization of dry EDM performed in a pulsating magnetic field. CIRP Annals – Manufacturing Technology, 60(2011), 239-242.
• [34] D. UMBRELLO et al.: Analysis of the white layers formed during machining of hardened AISI 52100 steel under dry and cryogenic cooling conditions. Int. Journal of Advanced Manufacturing Technology, (2012).
• [35] P. GOVINDAN, S.S. JOSHI: Analysis of micro-cracks on machined surfaces in dry electrical discharge machining. Journal of Manufacturing Processes, 14(2012), 277-288.
• [36] R. TEIMOURI, H. BASERI: Improvement of dry EDM process characteristics using artificial soft computing methodologies. Prod. Eng. Res. Devel., (2012)6, 493-504.
• [37] M. KUNIEDA, Y. MIYOSHI, T. TAKAYA, N. NAKAJIMA, Y.Z. BO and M. YOSHIDA: High speed 3D milling by dry EDM. CIRP Annals Manufacturing Technology, 52(2003), 147-150.
• [38] G. SKRABALAK et al.: Optimization of dry EDM process. Procedia CIRP, 6(2013), 333-338.
• [39] D.J. HU: Experimental investigations into near-dry milling EDM of Stellite alloys. Int. J. Machining and Machinability of Materials, 7(2010), 1/2.
• [40] C.C. KAO et al.: Near- dry electrical discharge machining (EDM) process. Int. Journal of Machine Tools & Manufacture, 47(2007), 2273-2281.
• [41] T. JIA et al.: Near-Dry EDM Milling of Mirror-Like Surface Finish. Int. Journal of Electrical Machining, 13(2008)1.
• [42] T. JIA et al.: Experimental Study of the dry and near-dry electrical discharge milling processes. Journal of Manufacturing Science and Engineering, 130(2008).
• [43] L. LI et al.: Research on dry EDM processing performance with two kinds of pulse generator modes. Proc. PASME International Manufacturing Science and Engineering Conference, Vol. 1, Corvallis-Oregon 2011.
• [44] M. FUJIKI et al.: Gap control for near-dry EDM milling with lead angle. Int. Journal of Machine Tools and Manufactur, 10(2011), 77-83.
• [45] M. FUJIKI et al.: Tool path planning for near-dry EDM milling with lead angle on curved surfaces. Journal of Manufacturing Science and Engineering, 133(2011).
• [46] L. LIQING, S. YINGJIE: Study of dry EDM with oxygen mixed and cryogenic cooling approaches. Procedia CIRP, 6(2013), 345-351.
• [47] A.P. MALSHE et al.: Experimental investigation and characterization of a novel technique of nanoscale dry electro-machining. Journal of Manufacturing Processes, 14(2012), 443-451.
• [48] A.P. MALSHE et al.: A comparative study of the dry and wet nano-scale electromachining. Procedia CIRP, 6(2013), 627-632.
• [49] Q.H. ZHANG et al.: Research on material removal rate of powder mixed near dry electrical discharge machining. Int. J. Adv. Manuf. Technol., (2013)8.
• [50] R.K. GARG et al.: Review of research work in sinking EDM and WEDM on metal matrix composite materials. Int. Journal of Advanced Manufacturing Technology, (2010), 611-624.
• [51] A. ERDEN, D. TEMEL: Investigation on the use of water as a dielectric liquid in electric discharge machining. Proc. 22nd Machine Tool Design and Research Conference. Manchester 1981, 437-440.
• [52] M.L. JESWANI: Electrical discharge machining in distilled water. Wear, 72(1981), 81-88.
• [53] T.S. JILANI, P.C. PANDEY: Experimental investigations into the performance of water as dielectric in EDM. Int. Journal of Machine Tool Design and Research, 24(1984), 31-43.
• [54] W. KOENIG, L. JOERRES: An aqueous solution. CIRP Annals-Manufacturing Technology, 36(1987), 105-109.
• [55] W. KONIG, F.J. SIEBERS: Influence of the working medium on the removal process in EDM sinking. Production Engineering Division (Publication) PED, 64(1993), 649-658.
• [56] W. KONIG, F. KLOCKE, M. SPARRER: EDM–sinking using water-based dielectrics and electropolishing – a new manufacturing sequence in tool-making. Proc. 11th Int. Symposium on Electromachining (ISEM XI), Lausanne 1995, 225-234.
• [57] T. MASUZAWA, K. TANAKA, Y. NAKAMURA: Water-based dielectric solution for EDM. Ann. CIRP, 32(1983), 119-122.
• [58] T. MASUZAWA: Machining characteristics of EDM using water as dielectric fluid. Proc. 22nd Machine Tool Design and Research Conference, Manchester 1981, 441-447.
• [59] Y. LIU et al.: Die-sinking electrical discharge machining with oxygen-mixed water-in-oil emulsion working fluid. Proc. Institution of Mechanical Engineers. Journal of Engineering Manufacture, 20(2012)11.
• [60] Y. LIU et al.: Experimental characterization of sinking electrical discharge machining using water in oil emulsion as dielectric. Materials and Manufacturing Processes, 28(2013).
• [61] H.I. MEDELLIN et al.: Experimental study on electrodischarge machining in water of D2 tool steel using two different electrode materials. Proc. of the Institution of Mechanical Engineers. Journal of Engineering Manufacture, 223(2009), 1423-1430.
• [62] G. DUNNEBACKE: High performance electrical discharge machining using a water-based dielectric. Proc. 10th Int. Symposium for Electromachining (ISEM X), Magdeburg 1992, 170-182.
• [63] R. DEWES, D. ASPINWALL, J. BURROWS, M. PAUL, F. El-MENSHAWY: High speed machining-multi-function/hybrid systems. Proc. 4th Int. Conf. on Industrial Tooling, Southampton 2001, 91-100.
• [64] T. KARASAWA, M. KUNIEDA: EDM capability with poured dielectric fluids without a tub. Bull. Jpn. Soc. Precision Eng., 24(1990), 217-218.
• [65] B.W. PILLANS, M.H. EVENSEN, H.F. TAYLOR, P.T. EUBANK: Fiber optic diagnostic techniques applied to electrical discharge machining sparks. J. Appl. Phys., 91(2002), 1780-1786.
• [66] J.A. Mc GEOUGH: Advanced methods of machining. Chapman & Hall, London 2010.
• [67] J.P. KRUTH, L. STEVENS, L. FROYEN, B. LAUWERS, K.U. LEUVEN: Study of the white layer of a surface machined by die-sinking electrodischarge machining. Ann. CIRP, 44(1995), 169-172.
• [68] I. OGATA, Y. MUKOYAMA: Carburizing and decarburizing phenomena in EDMed surface. Int. J. Jpn. Soc. Precision Eng., 27(1993), 197-202.
• [69] S.L. CHEN, B.H. YAN, F.Y. HUANG: Influence of kerosene and distilled water as dielectric on the electric discharge machining characteristics of Ti-6Al-4V. Journal of Materials Processing Technology, 87(1999), 107-111.
• [70] R. KRANZ, F. WENDL, K.D. WUPPER: Influence of EDM conditions on the toughness of tool steels. Thyssen Edelstahl Technische Berichte 1990, 100-105.
• [71] S. EVERTZ, A. EISENTRAEGER, W. DOTTI, F. KLOCKE, A. KARDEN, G. ANTONOGLOU: Environmental and industrial hygiene in connection with electrical discharge machining at high discharge energies. Proc. 13th International Symposium on Electromachining (ISEM XIII), 2001, 193-210.
• [72] B. BOMMELI: Study of the harmful emanations resulting from the machining by electro-erosion. Proc. 7th Int. Symposium on Electromachining (ISEM VII), 1983, 469-478.