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Guo C, Luo L, Liang Z, Li H, Wang X, Xu B. Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium. MICROMACHINES 2024; 15:434. [PMID: 38675246 PMCID: PMC11051845 DOI: 10.3390/mi15040434] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/23/2024] [Revised: 03/14/2024] [Accepted: 03/22/2024] [Indexed: 04/28/2024]
Abstract
Die-sinking micro-electrical discharge machining (micro-EDM) is a potential method used to fabricate intricate structures without complex electrode motion planning and compensation. However, machining efficiency and poor discharge states are still bottlenecks. This study conducted a comparative investigation into the impact of ultrasonic vibration on die-sinking micro-EDM of polycrystalline diamond (PCD) and pure titanium (TA2). By adjusting discharge parameters, this study systematically evaluated the influence of ultrasonic vibration on these two materials based on discharge waveforms, motion trajectories, effective discharge counts and groove profiles. At an open-circuit voltage of 100 V, ultrasonic vibration promotes die-sinking micro-EDM of PCD. However, when the open-circuit voltage increases to 200 V, ultrasonic vibration exhibits inhibitory effects in general. Conversely, for TA2, ultrasonic vibration shows a promoting effect at both voltages, indicating the differences of ultrasonic vibration-assisted die-sinking micro-EDM on PCD and TA2. For PCD, ultrasonic cavitation improves the discharge gap environment, accelerating the removal of discharge debris. For TA2, due to its poor thermal conductivity, ultrasonic cavitation acts to break the arc, accelerating heat transfer. These research findings provide guidance for ultrasonic vibration-assisted die-sinking micro-EDM in industrial applications.
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Affiliation(s)
- Cheng Guo
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China; (L.L.); (H.L.); (X.W.); (B.X.)
- Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
| | - Longhui Luo
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China; (L.L.); (H.L.); (X.W.); (B.X.)
- Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
| | - Zhiqiang Liang
- School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China;
| | - Hao Li
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China; (L.L.); (H.L.); (X.W.); (B.X.)
- Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
| | - Xiawen Wang
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China; (L.L.); (H.L.); (X.W.); (B.X.)
- Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
| | - Bin Xu
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China; (L.L.); (H.L.); (X.W.); (B.X.)
- Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
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Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process. MATERIALS 2021; 14:ma14206192. [PMID: 34683784 PMCID: PMC8538354 DOI: 10.3390/ma14206192] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/06/2021] [Revised: 10/11/2021] [Accepted: 10/14/2021] [Indexed: 11/17/2022]
Abstract
Difficulty in debris removal and the transport of fresh dielectric into discharge gap hinders the process performance of electrical discharge machining (EDM) process. Therefore, in this work, an economical low frequency vibration platform was developed to improve the performance of EDM through vibration assistance. The developed vibratory platform functions on an eccentric weight principle and generates a low frequency vibration in the range of 0–100 Hz. The performance of EDM was evaluated in terms of the average surface roughness (Ra), material removal rate (MRR), and tool wear rate (TWR) whilst varying the input machining parameters viz. the pulse-on-time (Ton), peak current (Ip), vibration frequency (VF), and tool rotational speed (TRS). The peak current was found to be the most significant parameter and contributed by 78.16%, 65.86%, and 59.52% to the Ra, MRR, and TWR, respectively. The low frequency work piece vibration contributed to an enhanced surface finish owing to an improved flushing at the discharge gap and debris removal. However, VF range below 100 Hz was not found to be suitable for the satisfactory improvement of the MRR and reduction of the TWR in an electrical discharge drilling operation at selected machining conditions.
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Sabyrov N, Jahan MP, Bilal A, Perveen A. Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)-An Overview. MATERIALS 2019; 12:ma12030522. [PMID: 30744142 PMCID: PMC6384716 DOI: 10.3390/ma12030522] [Citation(s) in RCA: 34] [Impact Index Per Article: 6.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/04/2018] [Revised: 12/23/2018] [Accepted: 01/08/2019] [Indexed: 11/22/2022]
Abstract
Many of the industrial processes, including material removal operation for shape generation on the surface of material, exploit the assistance of ultrasonic vibrations. This trend of using ultrasonic vibration in order to improve the process performance is becoming more and more prominent recently. One of the significant applications of this ultrasonic vibration is in the industrial processes such as Electro-discharge machining (EDM), where ultrasonic vibration (UV) is inserted as a medium for enhancing the process performance. Mostly ultrasonic vibration is applied along with the EDM process to increase the efficiency of the process through debris cleansing from the sparking gap. There have been significant changes in ultrasonic assisted technology during the past years. Due to its inherent advantages, ultrasonic assistance infiltrated in different areas of EDM, such as wire cut EDM, micro EDM and die sinking EDM. This article presents an overview of ultrasonic vibration applications in electric discharge machining. This review provides information about modes of UV application, impacts on parameters of performance, optimization and process designing on difficult-to-cut materials. On the bases of available research works on ultrasonic vibration assisted EDM, current challenges and future research direction to improve the process capabilities are identified. Literature suggested improved material removal rate (MRR), increased surface roughness (SR) and tool wear ratio (TWR) due to the application of ultrasonic vibration assisted EDM. However, tool wear and surface roughness can be lessened with the addition of carbon nanofiber along with ultrasonic vibration. Moreover, the application of ultrasonic vibration to both tool and workpiece results in higher MRR compared to its application to single electrode.
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Affiliation(s)
- Nurbol Sabyrov
- Department of Mechanical & Aerospace Engineering, Nazarbayev University, Astana 010000, Kazakhstan.
| | - M P Jahan
- Department of Mechanical Engineering, Miami University, Oxford, OH 45056, USA.
| | - Azat Bilal
- Department of Mechanical & Aerospace Engineering, Nazarbayev University, Astana 010000, Kazakhstan.
| | - Asma Perveen
- Department of Mechanical & Aerospace Engineering, Nazarbayev University, Astana 010000, Kazakhstan.
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Goiogana M, Sarasua J, Ramos J. Ultrasonic Assisted Electrical Discharge Machining for High Aspect Ratio Blind Holes. ACTA ACUST UNITED AC 2018. [DOI: 10.1016/j.procir.2017.12.026] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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