Skip to main content
SpringerLink
Log in

Effect of solution conductivity on tool electrode wear in electrochemical discharge drilling of nickel-based alloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Electrochemical discharge drilling (ECDD) is a hybrid machining process for fabricating small holes in nickel-based superalloys. In this study, the effects of solution conductivity on tool electrode wear during ECDD process are investigated. The experiments are performed using deionised water and NaNO3 solutions with different conductivities as working fluids. Machining current waveforms and hole-drilling results are analysed. The aim of this study is to investigate the reduction in tool electrode wear while obtaining good quality drill holes by ECDD with suitable solution conductivity. Experimental results show that the ECDD process using a NaNO3 working fluid with a conductivity of approximately 4.0 mS/cm results in optimal quality holes with the low tool electrode wear, and the tool electrode relative wear ratio is reduced by 65.4% as the working fluid conductivity changes from 0.005 to 4.0 mS/cm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Dai P, Li SX (2014) Recent advances in the study of film cooling on the gas turbine blade. Adv Mater Res 971-973:143–147

    Article  Google Scholar 

  2. Dong YW, Li XL, Zhao Q, Li XJ, Dou YQ (2017) Geometrical modeling to improve the accuracy of drilled cooling holes on turbine blades. Int J Adv Manuf Technol 93:4409–4428

    Article  Google Scholar 

  3. Li CJ, Li Y, Tong H, Zhao L, Kong QC, Wang ZQ (2016) An EDM pulse power generator and its feasible experiments for drilling film cooling holes. Int J Adv Manuf Technol 87:1813–1821

    Article  Google Scholar 

  4. Ay M, Çaydaş U, Hasçalık A (2013) Optimization of micro-EDM drilling of inconel 718 superalloy. Int J Adv Manuf Technol 66:1015–1023

    Article  Google Scholar 

  5. Wen ZX, Huang S, Gao HS, Yue ZF (2017) Experimental investigation on low cycle fatigue properties of GH3536 alloy with film cooling holes in different drilling processes. Eng Fail Anal 82:190–197

    Article  Google Scholar 

  6. Liu K, Lauwers B, Reynaerts D (2010) Process capabilities of micro-EDM and its applications. Int J Adv Manuf Technol 47(1–4):11–19

    Article  Google Scholar 

  7. Bassoli E, Denti L, Gatto A, Iuliano L (2016) Influence of electrode size and geometry in electro-discharge drilling of Inconel 718. Int J Adv Manuf Technol 86:2329–2337

    Article  Google Scholar 

  8. Gao Q (2018) Impact of electrode length on EDM inclined hole drilling process. Int J Adv Manuf Technol 94:1171–1175

    Article  Google Scholar 

  9. Luis CJ, Puertas I, Villa G (2005) Material removal rate and electrode wear study on the EDM of silicon carbide. J Mater Process Technol 164:889–896

    Article  Google Scholar 

  10. Wang CC, Chow HM, Yang LD, Lu CT (2009) Recast layer removal after electrical discharge machining via Taguchi analysis: a feasibility study. J Mater Process Technol 209:4134–4140

    Article  Google Scholar 

  11. Zhu D, Wang W, Fang XL, Qu NS, Xu ZY (2010) Electrochemical drilling of multiple holes with electrolyte-extraction. CIRP Ann Manuf Technol 59(1):239–242

    Article  Google Scholar 

  12. Wang XD, Qu NS, Fang XL, Li HS (2016) Electrochemical drilling with constant electrolyte flow. J Mater Process Technol 238:1–7

    Article  Google Scholar 

  13. Fang XL, Qu NS, Zhang YD, Xu ZY, Zhu D (2014) Improvement of hole exit accuracy in electrochemical drilling by applying a potential difference between an auxiliary electrode and the anode. J Mater Process Technol 214(3):556–564

    Article  Google Scholar 

  14. Fang XL, Qu NS, Li HS, Zhu D (2013) Enhancement of insulation coating durability in electrochemical drilling. Int J Adv Manuf Technol 68:2005–2013

    Article  Google Scholar 

  15. He XL, Wang YK, Wang ZL, Zeng ZQ (2013) Micro-hole drilled by EDM-ECM combined processing. Key Eng Mater 562-565:52–56

    Article  Google Scholar 

  16. Nguyen MD, Rahman M, Wong YS (2012) Simultaneous micro-EDM and micro-ECM in low-resistivity deionized water. Int J Mach Tool Manu 54-55:55–65

    Article  Google Scholar 

  17. Nguyen MD, Rahman M, Wong YS (2013) Modeling of radial gap formed by material dissolution in simultaneous micro-EDM and micro-ECM drilling using deionized water. Int J Mach Tool Manu 66:95–101

    Article  Google Scholar 

  18. Nguyen MD, Rahman M, Wong YS (2013) Transitions of micro-EDM/SEDCM /micro-ECM milling in low-resistivity deionized water. Int J Mach Tool Manu 69:48–56

    Article  Google Scholar 

  19. Zhang Y, Xu ZY, Zhu D, Qu NS, Zhu Y (2016) Drilling of film cooling holes by a EDM/ECM in situ combined process using internal and side flushing of tubular electrode. Int J Adv Manuf Technol 83:505–517

    Article  Google Scholar 

  20. Singh T, Dvivedi A (2016) Developments in electrochemical discharge machining: a review on electrochemical discharge machining, process variants and their hybrid methods. Int J Mach Tool Manu 105:1–13

    Article  Google Scholar 

  21. Lauwers B, Klocke F, Klink A, Tekkaya AE, Neugebauer R, Mcintosh D (2014) Hybrid processes in manufacturing. CIRP Ann Manuf Technol 63:561–583

    Article  Google Scholar 

  22. Goud M, Sharma AK, Jawalkar C (2016) A review on material removal mechanism in electrochemical discharge machining (ECDM) and possibilities to enhance the material removal rate. Precis Eng 45:1–17

    Article  Google Scholar 

  23. Yang CK, Wu KL, Hung JC, Lee SM, Lin JC, Yan BH (2011) Enhancement of ECDM efficiency and accuracy by spherical tool electrode. Int J Mach Tool Manu 51(6):528–535

    Article  Google Scholar 

  24. Huang SF, Liu Y, Li J, Hu HX, Sun LY (2014) Electrochemical discharge machining micro-hole in stainless steel with tool electrode high-speed rotating. Mater Manuf Process 29(5):634–637

    Article  Google Scholar 

  25. Coteata M, Schulze H, Slatineanu L (2011) Drilling of difficult-to-cut steel by electrochemical discharge machining. Mater Manuf Process 26(12):1466–1472

    Article  Google Scholar 

  26. Behroozfar A, Razfar MR (2016) Experimental study of the tool wear during the electrochemical discharge machining. Mater Manuf Process 31(5):574–580

    Article  Google Scholar 

  27. Chavoshi SZ, Behagh AM (2014) A note on influential control parameters for drilling of hard-to-machine steel by electrochemical discharge machining. Int J Adv Manuf Technol 71:1883–1887

    Article  Google Scholar 

  28. Tao XT, Liu ZD, Qiu MB, Tian ZJ, Shen LD (2018) Research on an EDM-based unitized drilling process of TC4 alloy. Int J Adv Manuf Technol 97:867–875

    Article  Google Scholar 

  29. Jui SK, Kamaraj AB, Sundaram MM (2013) High aspect ratio micromachining of glass by electrochemical discharge machining (ECDM). J Manuf Process 15(4):460–466

    Article  Google Scholar 

  30. Zhang Y, Xu ZY, Zhu D, Xing J (2015) Tube electrode high-speed electrochemical discharge drilling using low-conductivity salt solution. Int J Mach Tool Manu 92:10–18

    Article  Google Scholar 

  31. Zhang Y, Xu ZY, Xing J, Zhu D (2016) Effect of tube-electrode inner diameter on electrochemical discharge machining of nickel-based superalloy. Chin J Aeronaut 29(4):1003–1110

    Google Scholar 

  32. Dong SL, Wang ZL, Wang YK (2017) High-speed electrochemical discharge drilling (HSECDD) for micro-holes on C17200 beryllium copper alloy in deionized water. Int J Adv Manuf Technol 88:827–835

    Article  Google Scholar 

  33. Yin QF, Wang BR, Zhang YB, Liu GM (2014) Research of lower tool electrode wear in simultaneous EDM and ECM. J Mater Process Technol 214(8):1759–1768

    Article  Google Scholar 

Download references

Funding

This research was sponsored by the National Natural Science Foundation of China (51475237), China, Outstanding Youth Foundation of Jiangsu province of China (BK20170031), China, Fundamental Research Funds for the Central Universities (NE2014104), China, and Postgraduate Research & Practice Innovation Program of Jiangsu Province (KYCX18_0258), China.

Author information

Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, 29 Yudao Street, Nanjing, 210016, China

    Chenxiang Zhang, Zhengyang Xu, Yusen Hang & Jun Xing

Authors
  1. Chenxiang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhengyang Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yusen Hang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jun Xing
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zhengyang Xu.

Ethics declarations

Conflict of interest

The authors declare that they have no conflicts of interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, C., Xu, Z., Hang, Y. et al. Effect of solution conductivity on tool electrode wear in electrochemical discharge drilling of nickel-based alloy. Int J Adv Manuf Technol 103, 743–756 (2019). https://doi.org/10.1007/s00170-019-03492-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-03492-w

Keywords

Search

Navigation