Advertisement

High-speed vibration-assisted electro-arc machining

  • Guang Zhu
  • Min Zhang
  • Qinhe ZhangEmail author
  • Kan Wang
ORIGINAL ARTICLE
  • 45 Downloads

Abstract

The material removal rate (MRR) of electrical discharge machining (EDM) is low when machining difficult-to-machine materials; to address this issue, a novel high-speed electrical machining (EM) method, namely vibration-assisted electro-arc machining (VEAM), is proposed in this study. In the process of VEAM, a graphite pipe was used as a tool electrode with high-pressure tap water medium applied inside. A direct-current power supply was used to generate enough energy for the machining process and vibration was applied onto the workpiece through the workbench. In our experiments, high-speed steel W9Mo3Cr4V serving as the workpiece was fixed on a workbench and a workpiece vibration along the Z-axis was provided by an electromagnetic vibration table through the workbench. The results showed that the superposition of vibration in electro-arc machining (EAM) can improve the MRR excellently. The maximum MRR of 8565 mm3/min was achieved with a 33% increase in EAM. The working mechanism of VEAM was investigated and comparative experiments with different machining parameters were conducted. The effects of the vibration frequency and amplitude were studied while the MRR, surface roughness (Rz), relative electrode wear ratio (REWR), and white layer thickness (WLT) and were selected as the evaluations. The results indicated that the novel high-speed VEAM method has great potential to obtain a higher MRR and a lower REWR.

Keywords

Vibration-assisted electro-arc machining Vibration Material removal rate High-speed machining 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgments

The work is financially supported by grants from the National Natural Science Foundation of China (Grant no.: 51775316), the National Youth Science Foundation (no.: 51705236), the Breeding Project of Inter discipline of Shandong University (no. 2016JC008).

References

  1. 1.
    Ho K, Newman S (2003) State of the art electrical discharge machining (EDM). Int J Mach Tools Manuf 43:1287–1300CrossRefGoogle Scholar
  2. 2.
    Marafona J, Wykes C (2000) A new method of optimising material removal rate using EDM with copper–tungsten electrodes. Int J Mach Tool Manu 40:153–164CrossRefGoogle Scholar
  3. 3.
    Tsai HC, Yan BH, Huang FY (2003) EDM performance of Cr/Cu-based composite electrodes. Int J Mach Tools Manuf 43:245–252CrossRefGoogle Scholar
  4. 4.
    Kunleda M, Miyoshi Y, Takaya T, Nakajima N, ZhanBo Y, Yoshida M (2003) High speed 3D milling by dry EDM. CIRP Ann Manuf Technol 52:147–150CrossRefGoogle Scholar
  5. 5.
    Yeo S, Murali M, Cheah H (2004) Magnetic field assisted micro electro-discharge machining. J Micromech Microeng 14:1526–1529CrossRefGoogle Scholar
  6. 6.
    Zhao WS, Meng QG, Wang ZL (2002) The application of research on powder mixed EDM in rough machining. J Mater Process Technol 129:30–33CrossRefGoogle Scholar
  7. 7.
    Razak MA, Abdul-Rani AM, Nanimina AM (2015) Improving EDM efficiency with silicon carbide powder-mixed dielectric fluid. Int J Mater Mech Manuf 3:40–43Google Scholar
  8. 8.
    Lin M-Y, Tsao C-c, Hsu C-y, Chiou A-h, Huang P-c, Lin Y-c (2013) Optimization of micro milling electrical discharge machining of Inconel 718 by Grey-Taguchi method. Trans Nonferrous Metals Soc China 23:661–666CrossRefGoogle Scholar
  9. 9.
    Dave HK, Mathai VJ, Mayanak MK, Raval HK, Desai KP (2016) Study on effect of process parameters on overcut and tool wear rate during micro-electro-discharge slotting process. Int J Adv Manuf Technol 85:2049–2060CrossRefGoogle Scholar
  10. 10.
    Ayesta I, Izquierdo B, Sánchez J, Ramos J, Plaza S, Pombo I et al (2013) Influence of EDM parameters on slot machining in C1023 aeronautical alloy. Procedia CIRP 6:129–134CrossRefGoogle Scholar
  11. 11.
    Han F, Wang Y, Zhou M (2009) High-speed EDM milling with moving electric arcs. Int J Mach Tools Manuf 49:20–24CrossRefGoogle Scholar
  12. 12.
    Wang F, Liu Y, Tang Z, Ji R, Zhang Y, Shen Y (2013) Ultra-high-speed combined machining of electrical discharge machining and arc machining, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manuf acture p. 0954405413506194Google Scholar
  13. 13.
    Zhao W, Gu L, Xu H, Li L, Xiang X (2013) A novel high efficiency electrical erosion process–blasting erosion arc machining. Procedia Cirp 6:621–625CrossRefGoogle Scholar
  14. 14.
    Zhang M, Zhang Q, Dou L, Zhu G, Dong C (2016) An independent discharge status detection method and its application in EAM milling. Int J Adv Manuf Technol 87:909–918CrossRefGoogle Scholar
  15. 15.
    Meshcheriakov G, Nosulenko V, Meshcheriakov N, Bokov V (1988) Physical and technological control of arc dimensional machining. CIRP Ann Manuf Technol 37:209–212CrossRefGoogle Scholar
  16. 16.
    Hongping A, Kiyoshi H (1985) Phenomenon of Welding Arc: Machinery Industry PressGoogle Scholar
  17. 17.
    Eubank PT, Patel MR, Barrufet MA, Bozkurt B (1993) Theoretical models of the electrical discharge machining process. III. The variable mass, cylindrical plasma model. J Appl Phys 73:7900–7909CrossRefGoogle Scholar
  18. 18.
    Zhiguang H, Zhidong L, Mingbo Q, Xiangzhi W, Zhongli C (2014) Discharge characteristics of cool electrode in EDM based on monopulse discharge. Int J Adv Manuf Technol 75:731–738CrossRefGoogle Scholar
  19. 19.
    Yin S (2007) Craft foundation of gas shielded welding. China Machine Press, BeijingGoogle Scholar
  20. 20.
    Zhou JP, Xu Y, Zhang JZ, Ma B (2012) Analysis and study on surface quality of workpiece of short electric arc machining process. In: Key Eng Mater, pp 47–51Google Scholar
  21. 21.
    Zheng CK (2009) Plasma physics. Peking University Press, BeijingGoogle Scholar
  22. 22.
    Yin SY (2007) Craft foundation of gas shielded welding. Machine PressGoogle Scholar
  23. 23.
    Zhang M, Zhang Q, Dou L, Liu Q, Dong C (2016) Effects of flushing on electrical discharge machining and electro-arc machining. Proc Inst Mech Eng B J Eng Manuf 230:293–302CrossRefGoogle Scholar
  24. 24.
    Zhang M, Zhang Q, Wang H, Liu G, Guo T (2015) Research on a single pulse discharge to discriminate EDM and EAM based on the plasma tunnel and crater geometry. J Mater Process Technol 219:248–256CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Guang Zhu
    • 1
    • 2
  • Min Zhang
    • 3
  • Qinhe Zhang
    • 1
    • 2
    Email author
  • Kan Wang
    • 1
    • 2
  1. 1.Key Laboratory of High Efficiency and Clean Mechanical Manufacture (Ministry of Education), School of Mechanical EngineeringShandong UniversityJinan CityPeople’s Republic of China
  2. 2.National Demonstration Center for Experimental Mechanical Engineering EducationShandong UniversityJinanChina
  3. 3.School of Mechanical EngineeringNanjing Institute of TechnologyNanjingChina

Personalised recommendations