Skip to main content
SpringerLink
Log in

Water-in-oil nanoemulsion dielectric for both rough and finishing electrical discharge machining

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

Abstract

The modern industry which widely utilized sinking electrical discharge machining (EDM) with kerosene has many problems including low processing efficiency, unsafety, unfriendly environmental impact, and poor machined surface accompanying with recast layer. In this paper, a new water-in-oil (W/O) nanoemulsion dielectric is proposed to overcome these shortcomings of conventional sinking EDM. The machining performance and mechanism of sinking EDM using W/O nanoemulsion are investigated in both rough and finishing machining by comparing with kerosene. The main characteristic parameters for evaluating machining performance, including material removal rate (MRR) and relative electrode wear rate (REWR) in rough machining, and machined surface quality in finishing machining are studied. Compared with kerosene, using W/O nanoemulsion as a dielectric in sinking EDM, a nearly 34 times higher MRR and a relatively lower REWR are obtained in rough machining, and a better machined surface with no recast layer is attained in finishing machining.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Rajeswari R, Shunmugam MS (2019) Investigations into process mechanics of rough and finish die sinking EDM using pulse train analysis. Int J Adv Manuf Technol 100(5–8):1945–1964

    Article  Google Scholar 

  2. Qudeiri JE, Mourad AH, Ziout A, Abidi MH, Elkaseer A (2018) Electric discharge machining of titanium and its alloys. Int J Adv Manuf Technol 96(1–4):1319–1339

    Article  Google Scholar 

  3. Leão FN, Pashby IR (2004) A review on the use of environmentally-friendly dielectric fluids in electrical discharge machining. J Mater Process Technol 149(1–3):341–346

    Article  Google Scholar 

  4. Shabgard MR, Gholipoor A, Baseri H (2016) A review on recent developments in machining methods based on electrical discharge phenomena. Int J Adv Manuf Technol 87(5–8):2081–2097

    Article  Google Scholar 

  5. Nguyen TD, Nguyen PH, Banh LT (2019) Die steel surface layer quality improvement in titanium μ-powder mixed die sinking electrical discharge machining. Int J Adv Manuf Technol 100(9–12):2637–2651

    Article  Google Scholar 

  6. Peças P, Henriques E (2008) Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric (PMD-EDM). Int J Adv Manuf Technol 37(11–12):1120–1132

    Article  Google Scholar 

  7. Amorim FL, Dalcin VA, Soares P, Mendes LA (2017) Surface modification of tool steel by electrical discharge machining with molybdenum powder mixed in dielectric fluid. Int J Adv Manuf Technol 91(1–4):341–350

    Article  Google Scholar 

  8. Zhao WS, Meng QG, Wang ZL (2002) The application of research on powder mixed EDM in rough machining. J Mater Process Technol 129(1–3):30–33

    Article  Google Scholar 

  9. Wu KL, Yan BH, Lee JW, Ding CG (2009) Study on the characteristics of electrical discharge machining using dielectric with surfactant. J Mater Process Technol 209(8):3783–3789

    Article  Google Scholar 

  10. Masuzawa T, Tanaka K, Nakamura Y, Kinoshita N (1983) Water-based dielectric solution for EDM. CIRP Ann Manuf Technol 32(1):119–122

    Article  Google Scholar 

  11. Jeswani ML (1981) Electrical discharge machining in distilled water. Wear 72(1):81–88

    Article  Google Scholar 

  12. Jilani ST, Pandey PC (1984) Experimetnal investigations into the performance of water as dielectric in EDM. Int J Mach Tool Des Res 24(1):31–43

    Article  Google Scholar 

  13. Yu Z, Kunieda M (1999) Study on material removal rate of EDM in deionized water. J Jpn Soc Electr Mach Eng 33(72):28–36

    Google Scholar 

  14. Koenig W, Joerres L (1987) Aqueous solutions of organic compounds as dielectrics for EDM sinking. CIRP Ann Manuf Technol 36(1):105–109

    Article  Google Scholar 

  15. Zeng Z, Wang Y, Wang Z, Shan D, He X (2012) A study of micro-EDM and micro-ECM combined milling for 3D metallic micro-structures. Precis Eng 36(3):500–509

    Article  Google Scholar 

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

    Article  Google Scholar 

  17. Nguyen MD, Rahman M, San Wong Y (2013) Transitions of micro-EDM/SEDCM/micro-ECM milling in low-resistivity deionized water. Int J Mach Tools Manuf 69:48–56

    Article  Google Scholar 

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

    Article  Google Scholar 

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

    Article  Google Scholar 

  20. Pan H (2014) Study of the preparation methods and properties of water-inoil (W/O) nanoemulsions using low-energy method. Shandong University.

  21. Yeo SH, New AK (1999) A method for green process planning in electric discharge machining. Int J Adv Manuf Technol 15(4):287–291

    Article  Google Scholar 

  22. Zhang Y, Liu Y, Ji R, Wang F, Cai B, Li H (2011) Application of variable frequency technique on electrical dehydration of water-in-oil emulsion. Colloids Surf A Physicochem Eng Asp 386(1–3):185–190

    Article  Google Scholar 

  23. Samantray PK, Karthikeyan P, Reddy KS (2006) Estimating effective thermal conductivity of two-phase materials. Int J Heat Mass Transf 49(21–22):4209–4219

    Article  MATH  Google Scholar 

  24. Gu L, Li L, Zhao W, Rjaurkar KP (2011) An efficient and economical rapid-tooling method for die-sinking electrical discharge machining. J Manuf Sci Eng 133(5):051004

    Article  Google Scholar 

  25. Gu L, Li L, Zhao W, Rajurkar KP (2012) Electrical discharge machining of Ti6Al4V with a bundled electrode. Int J Mach Tools Manuf 53(1):100–106

    Article  Google Scholar 

  26. Hasçalık A, Çaydaş U (2007) Electrical discharge machining of titanium alloy (Ti–6Al–4V). Appl Surf Sci 253(22):9007–9016

    Article  Google Scholar 

  27. Valaki JB, Rathod PP (2016) Assessment of operational feasibility of waste vegetable oil based bio-dielectric fluid for sustainable electric discharge machining (EDM). Int J Adv Manuf Technol 87(5–8):1509–1518

    Article  Google Scholar 

  28. Peças P, Henriques E (2009) Intrinsic innovations of die sinking electrical discharge machining technology: estimation of its impact. Int J Adv Manuf Technol 44(9–10):880–889

    Article  Google Scholar 

  29. Haas P, Pontelandolfo P, Perez R (2013) Particle hydrodynamics of the electrical discharge machining process. Part 1: Physical considerations and wire EDM process improvement. Procedia CIRP 6:41–46

    Article  Google Scholar 

  30. Kliuev M, Baumgart C, Büttner H, Wegener K (2018) Flushing velocity observations and analysis during EDM drilling. Procedia CIRP 77:590–593

    Article  Google Scholar 

  31. Wang F, Liu Y, Zhang Y, Tang Z, Ji R, Zheng C (2014) Compound machining of titanium alloy by super high speed EDM milling and arc machining. J Mater Process Technol 214(3):531–538

    Article  Google Scholar 

  32. Xu H, Gu L, Chen J, Hu J, Zhao W (2015) Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining. Int J Adv Manuf Technol 79(5–8):937–947

    Article  Google Scholar 

  33. Shen Y, Liu Y, Zhang Y, Dong H, Sun W, Wang X, Zheng C, Ji R (2015) High-speed dry electrical discharge machining. Int J Mach Tools Manuf 93:19–25

    Article  Google Scholar 

  34. Shen Y, Liu Y, Sun W, Zhang Y, Dong H, Zheng C, Ji R (2016) High-speed near dry electrical discharge machining. J Mater Process Technol 233:9–18

    Article  Google Scholar 

  35. Xia H, Kunieda M, Nishiwaki N (1996) Removal amount difference between anode and cathode in EDM process. IJEM 1:45–52

    Article  Google Scholar 

  36. Marafona J (2007) Black layer characterisation and electrode wear ratio in electrical discharge machining (EDM). J Mater Process Technol 184(1–3):27–31

    Article  Google Scholar 

  37. Kunieda M, Kobayashi T (2004) Clarifying mechanism of determining tool electrode wear ratio in EDM using spectroscopic measurement of vapor density. J Mater Process Technol 149(1–3):284–288

    Article  Google Scholar 

Download references

Funding

The work is partially supported by the Fundamental Research Funds for the Central Universities (Grant No. 16CX06016A), the Graduate Innovation Project of China University of Petroleum (East China) (Grant No. YCXJ2016058), the Key Pre-Research Foundation of Military Equipment of China (Grant No. 6140923030702), and the National Natural Science Foundation of China (Grant No. 51774316).

Author information

Authors and Affiliations

  1. College of Mechanical and Electronic Engineering, China University of Petroleum (East China), Qingdao, 266580, Shandong, China

    Hang Dong, Yonghong Liu, Tong Liu, Ming Li, Yu Zhou, Dege Li & Qiang Sun

Authors
  1. Hang Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yonghong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ming Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yu Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Dege Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Qiang Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yonghong Liu.

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

Dong, H., Liu, Y., Liu, T. et al. Water-in-oil nanoemulsion dielectric for both rough and finishing electrical discharge machining. Int J Adv Manuf Technol 104, 1485–1495 (2019). https://doi.org/10.1007/s00170-019-04028-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04028-y

Keywords

Search

Navigation