Skip to main content
SpringerLink
Log in

Surface integrity of Inconel 718 in high-speed electrical discharge machining milling using air dielectric

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

Abstract

This paper proposes a novel, efficient, and environmental friendly machining method named high-speed dry electrical discharge machining (EDM) milling. The material removal rate of this method is much higher than that of conventional EDM and is also higher than that of traditional mechanical machining method for materials that are “difficult to machine.” Nickel-based superalloy Inconel 718 is widely used in the aerospace field as its surface integrity exerts significant effects. In this study, the microscopic characteristics, such as surface roughness, re-solidified layer, micro-hardness, micro-crack, and micro-void, of the machined Inconel 718 in high-speed EDM milling using air dielectric were studied compared with those using liquid dielectric. The formation mechanism of the microscopic characteristics was revealed. Experimental results showed that the machined Inconel 718 in high-speed EDM milling using air dielectric exhibited smaller surface roughness, thinner thickness of re-solidified layer, and smaller and less micro-cracks compared with those using liquid dielectric. Theoretical and technical foundations were laid for the industrial application of this novel machining method.

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

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

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. Prihandana GS, Sriani T, Mahardika M, Hamdi M, Miki N, Wong YS, Mitsui K (2014) Application of powder suspended in dielectric fluid for fine finish micro-EDM of Inconel 718. Int J Adv Manuf Technol 75:599–613

    Article  Google Scholar 

  2. Kuppan P, Rajadurai A, Narayanan S (2008) Influence of EDM process parameters in deep hole drilling of Inconel 718. Int J Adv Manuf Technol 38:74–84

    Article  Google Scholar 

  3. 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 

  4. Wang F, Liu Y, Shen Y, Ji R, Tang Z, Zhang Y (2013) Machining performance of Inconel 718 using high current density electrical discharge milling. Mater Manuf Process 28:1147–1152

    Article  Google Scholar 

  5. 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 214:531–538

    Article  Google Scholar 

  6. Wang F, Liu Y, Tang Z, Ji R, Zhang Y, Shen Y (2014) Ultra-high-speed combined machining of electrical discharge machining and arc machining. Proc Inst Mech Eng Part B J Eng Manuf 228:663–672

    Article  Google Scholar 

  7. Weinert K, Inasaki I, Sutherland J, Wakabayashi T (2004) Dry machining and minimum quantity lubrication. CIRP Ann Manuf Technol 53(2):511–537

    Article  Google Scholar 

  8. Tao J, Shih A, Ni J (2008) Experimental study of the dry and near-dry electrical discharge milling processes. J Manuf Sci Eng Trans ASME 130(1):1–8

    Article  Google Scholar 

  9. Zhang Q, Du R, Zhang J, Zhang Q (2006) An investigation of ultrasonic assisted electrical discharge machining in gas. Int J Mach Tools Manuf 46(12–13):1582–1588

    Article  Google Scholar 

  10. Joshi S, Govindan P, Malshe A, Rajurkar K (2011) Experimental characterization of dry EDM performed in a pulsating magnetic field. CIRP Ann Manuf Technol 60:239–242

    Article  Google Scholar 

  11. 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 

  12. 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 

  13. Shen Y, Liu Y, Sun W, Dong H, Zhang Y, Wang X, Zheng C, Ji R (2015) High-speed dry compound machining of Ti6Al4V. J Mater Process Tech 224:200–207

    Article  Google Scholar 

  14. Yan B, Tsai H, Huang F (2005) The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. J Mach Tools Manuf 45:194–200

    Article  Google Scholar 

  15. Zhang Y, Liu Y, Ji R, Cai B (2011) Study of the recast layer of a surface machined by sinking electrical discharge machining using water-in-oil emulsion as dielectric. Appl Surf Sci 257:5989–5997

    Article  Google Scholar 

  16. Liew P, Yan J, Kuriyagawaa T (2013) Experimental investigation on material migration phenomena in micro-EDM of reaction-bonded silicon carbide. Appl Surf Sci 276:731–743

    Article  Google Scholar 

  17. Marashi H, Sarhan A, Hamdi M (2015) Employing Ti nano-powder dielectric to enhance surface characteristics in electrical discharge machining of AISI D2 steel. Appl Surf Sci 357:892–907

    Article  Google Scholar 

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

    Article  Google Scholar 

  19. Curodeau A, Richard M, Frohn-Villeneuve L (2004) Molds surface finishing with new EDM process in air with thermoplastic composite electrodes. J Mater Process Tech 149:278–283

    Article  Google Scholar 

  20. Zhang C (2012) Study of small cracks on nano composite ceramics cut by WEDM. Int J Adv Manuf Technol 83:187–192

    Article  Google Scholar 

  21. Ekmekci B, Tekkaya A, Erden A (2006) A semi-empirical approach for residual stresses in electric discharge machining (EDM). J Mach Tools Manuf 46:858–868

    Article  Google Scholar 

  22. Ekmekci B (2007) Residual stresses and white layer in electric discharge machining (EDM). Appl Surf Sci 253:9234–9240

    Article  Google Scholar 

  23. Umbrello D (2013) Investigation of surface integrity in dry machining of Inconel 718. Int J Adv Manuf Technol 69:2183–2190

    Article  Google Scholar 

  24. Chang L, Sun W, Cui Y, Zhang F, Yang R (2014) Effect of heat treatment on microstructure and mechanical properties of the hot-isostatic-pressed Inconel 718 powder compact. J Alloys Comp 590:227–232

    Article  Google Scholar 

  25. Cai D, Zhang W, Nie P, Liu W, Yao M (2007) Dissolution kinetics of δ phase and its influence on the notch sensitivity of Inconel 718. Mater Charact 58:220–225

    Article  Google Scholar 

  26. Aleem B, Hashmi M, Yilbas B (2011) Laser controlled melting of pre-prepared Inconel 718 alloy surface. Opt Laser Eng 49:1314–1319

    Article  Google Scholar 

  27. Yilbas B, Akhtar S, Karatas C (2010) Laser surface treatment of Inconel 718 alloy: thermal stress analysis. Opt Laser Eng 48:740–749

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

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

    Yang Shen, Yonghong Liu, Hang Dong, Xianzhi Zhang, Xinlei Wu, Chao Zheng & Renjie Ji

  2. Capital Spaceflight Machinery Company, China Academy of Launch Vehicle Technology, Beijing, 100000, China

    Kun Zhang

  3. China Academy of Launch Vehicle Technology, China Aerospace Science and Technology Corporation, Beijing, 100000, China

    Lin Lv

Authors
  1. Yang Shen
    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. Hang Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Kun Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Lin Lv
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Xianzhi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Xinlei Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Chao Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Renjie Ji
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yonghong Liu.

Ethics declarations

Conflict of interest

We declare that we have no financial and personal relationships with other people or organizations that can inappropriately influence our work; there is no professional or other personal interest of any nature or kind in any product, service, and/or company that could be construed as influencing the position presented in, or the review of, the manuscript entitled “Surface integrity of Inconel 718 in high-speed electrical discharge machining milling using air dielectric.”

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shen, Y., Liu, Y., Dong, H. et al. Surface integrity of Inconel 718 in high-speed electrical discharge machining milling using air dielectric. Int J Adv Manuf Technol 90, 691–698 (2017). https://doi.org/10.1007/s00170-016-9332-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9332-7

Keywords

Search

Navigation