Skip to main content
SpringerLink
Log in

Research on material removal rate of powder mixed near dry electrical discharge machining

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

Abstract

Dry electrical discharge machining (EDM) is an environmentally friendly modification of traditional EDM, but the material removal rate (MRR) of dry EDM is very low. A new machining method called powder mixed near dry EDM (PMND-EDM), which can improve MRR effectively, is proposed. In order to find the relationship between processing parameters and processing effect and improve processing efficiency, the MRR of PMND-EDM is studied systematically. The main processing parameters, such as peak current, pulse on time, pulse off time, powder concentration, flow rate, air pressure, and tool rotational speed, on MRR of PMND-EDM are studied in experiments. The experimental results showed that the MRR of PMND-EDM increased with the increase of peak current, pulse on time, flow rate, and air pressure, decreased with the increase of pulse off time and tool rotational speed, and increased firstly and then decreased with the increase of powder concentration. The significant test for process parameters on MRR of PMND-EDM is carried out through orthogonal design experiment. Analysis of variance for the result of orthogonal experiment indicates that peak current is significant at 99 % confidence level, pulse on time is significant at 95 % confidence level, and flow rate is significant at 90 % confidence level. Full factor experiments of peak current, pulse on time, and flow rate are conducted. The empirical formula of MRR is established based on experimental results. Its validity is demonstrated.

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. Kansal HK, Singh S, Kumar P (2005) Parameter optimization of powder mixed electrical discharge machining by response surface methodology. J Mater Process Technol 169:427–436

    Article  Google Scholar 

  2. Wei L, Zhang LX, Liu W, Jia ZY, Li AC (2012) A new interpolation method of variable period and step size in micro-EDM milling based on square constraint. Int J Adv Manuf Technol 63:621–629

    Article  Google Scholar 

  3. Assarzadeh S, Ghoreishi M (2013) A dual response surface-desirability approach to process modeling and optimization of Al2O3 powder-mixed electrical discharge machining (PMEDM) parameters. Int J Adv Manuf Technol 64:1459–1477

    Article  Google Scholar 

  4. Zhang LX, Jia ZY, Liu W, Li AC (2012) A two-stage servo feed controller of micro-EDM based on interval type-2 fuzzy logic. Int J Adv Manuf Technol 59:633–645

    Article  Google Scholar 

  5. Wang J, Han FZ, Zhao FL (2012) Improvement of EDM efficiency with a new adaptive control strategy. Int J Adv Manuf Technol l62:1025–1040

    Article  Google Scholar 

  6. Mai C, Hocheng H, Huang S (2012) Advantages of carbon nanotubes in electrical discharge machining. Int J Adv Manuf Technol 59:111–117

    Article  Google Scholar 

  7. Frohn-Villeneuve L, Curodeau A (2012) Dry die-sinking EDM with mouldable graphite–polymer electrode investigation of process parameters and pulse identification methods. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4244-7

    Google Scholar 

  8. Yan MT, Fang GR, Liu YT (2012) An experimental study on micro wire-EDM of polycrystalline diamond using a novel pulse generator. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4446-z

    Google Scholar 

  9. Gopalakannan S, Senthilvelan T (2012) EDM of cast Al/SiC metal matrix nanocomposites by applying response surface method. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4499-z

    Google Scholar 

  10. Wei CJ, Zhao L, Hu DJ, Ni J (2013) Electrical discharge machining of ceramic matrix composites with ceramic fiber reinforcements. Int J Adv Manuf Technol 64:187–194

    Article  Google Scholar 

  11. Puertas I, Luis CJ (2012) Optimization of EDM conditions in the manufacturing process of B4C and WC-Co conductive ceramics. Int J Adv Manuf Technol 59:575–582

    Article  Google Scholar 

  12. Pradhan MK (2013) Estimating the effect of process parameters on MRR, TWR and radial overcut of EDMed AISI D2 tool steel by RSM and GRA coupled with PCA. Int J Adv Manuf Technol. doi:10.1007/s00170-013-4780-9

    Google Scholar 

  13. Lin YC, Tsao CC, Hsu CY, Hung SK, Wen DC (2012) Evaluation of the characteristics of the microelectrical discharge machining process using response surface methodology based on the central composite design. Int J Adv Manuf Technol 62:1013–1023

    Article  Google Scholar 

  14. Bhattacharya A, Batish A, Singh G, Singla VK (2012) Optimal parameter settings for rough and finish machining of die steels in powder-mixed EDM. Int J Adv Manuf Technol 61:537–548

    Article  Google Scholar 

  15. Ramani V, Cassidenti ML (1985) Inert-gas electrical discharge machining. NASA Technical Brief Number NPO 15660

  16. Teimouri R, Baseri H (2012) Experimental study of rotary magnetic field-assisted dry EDM with ultrasonic vibration of workpiece. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4573-6

    Google Scholar 

  17. Govindan P, Joshi SS (2010) Experimental characterization of material removal in dry electrical discharge drilling. Int J Mach Tool Manuf 50:431–443

    Article  Google Scholar 

  18. Saha SK, Choudhury SK (2009) Experimental investigation and empirical modeling of the dry electric discharge machining process. Int J Mach Tool Manuf 49:297–308

    Article  Google Scholar 

  19. Kunieda M, Takaya T, Nakano S (2004) Improvement of dry EDM characteristics using piezoelectric actuator. CIRP Ann Manuf Technol 53(1):183–186

    Article  Google Scholar 

  20. Yoshida M, Kunieda M, Kaneko Y (1998) Improvement of material removal rate of dry EDM using piezoelectric actuator coupled with servo-feed mechanism. Proceedings of the 14th CAPE, Tokyo, Japan:283–288

  21. Zhang QH, Du R, Zhang JH, Zhang QB (2006) An investigation of ultrasonic-assisted electrical discharge machining in gas. Int J Mach Tool Manuf 46:1582–1588

    Article  Google Scholar 

  22. Zhang QH, Zhang JH, Deng JX, Qin Y, Niu ZW (2002) Ultrasonic vibration electrical discharge machining in gas. J Mater Process Technol 129:135–138

    Article  Google Scholar 

  23. Zhang QH, Zhang JH, Ren SF, Deng JX, Ai X (2004) Study on technology of ultrasonic vibration aided electrical discharge machining in gas. J Mater Process Technol 149(1–3):640–644

    Article  Google Scholar 

  24. Tao J, Shih AJ, Ni J (2008) Experimental study of the dry and near-dry electrical discharge milling processes. J Manuf Sci Eng 130:011002-1–011002-9

    Article  Google Scholar 

  25. Kao CC, Tao J, Shih AJ (2007) Near dry electrical discharge machining. Int J Mach Tool Manuf 47:2273–2281

    Article  Google Scholar 

  26. Boopathi S, Sivakumar K (2012) Experimental investigation and parameter optimization of near-dry wire-cut electrical discharge machining using multi-objective evolutionary algorithm. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4680-4

    Google Scholar 

  27. Gao Q, Zhang QH, Zhang JH (2009) Experimental study of powder-mixed near dry electrical discharge machining. Chin J Mech Eng 45(1):169–175

    Article  Google Scholar 

  28. Bai X, Zhang QH, Li TT, Zhang Y (2012) Research on the medium breakdown mechanism of powder mixed near dry electrical discharge machining. Chin J Mech Eng 48(7):186–192,198

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xue Bai, Qin-He Zhang, Ting-Yi Yang & Jian-Hua Zhang

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, Jinan, 250061, China

    Xue Bai, Qin-He Zhang, Ting-Yi Yang & Jian-Hua Zhang

Authors
  1. Xue Bai
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qin-He Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ting-Yi Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jian-Hua Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Qin-He Zhang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Bai, X., Zhang, QH., Yang, TY. et al. Research on material removal rate of powder mixed near dry electrical discharge machining. Int J Adv Manuf Technol 68, 1757–1766 (2013). https://doi.org/10.1007/s00170-013-4973-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-4973-2

Keywords

Search

Navigation