Skip to main content
SpringerLink
Log in

Influence of ion-rich plasma discharge channel on unusually high discharging points in reverse micro electrical discharge machining

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

Abstract

Different discharges occurring during machining in micro electrical discharge machining (MEDM) and its variants, viz. reverse MEDM (RMEDM) and wire EDM, affect the shape, size, surface roughness, and surface integrity of the generated surface. Of these different discharges, there are certain discharges with unusually high discharging points (well above open circuit voltage) during machining that have not been analysed till date. This study primarily aims in understanding the physical phenomenon behind occurrences of these unusual discharges specific to RMEDM process. This understanding should also hold good for MEDM and other electric discharge-based machining processes. A numerical model was developed taking into account the movement of ions and electrons in the dielectric during machining. The model predicted that the presence of ions only in the plasma discharge channel for a very short period of time during machining leads to occurrences of these unusually high discharging points (~170% of open circuit voltage, OCV) which was also verified from experiments (162–164% of OCV).

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

Similar content being viewed by others

References

  1. Roy T, Datta D, Balasubramaniam R (2018) Numerical modelling and simulation of surface roughness of 3-D hemispherical convex micro-feature generated by reverse micro-EDM. Int J Adv Manuf Technol 97:979–992. https://doi.org/10.1007/s00170-018-1971-4

    Article  Google Scholar 

  2. Kim BH, Park BJ, Chu CN (2006) Fabrication of multiple electrodes by reverse EDM and their application in micro ECM. J Micromechanics Microengineering 16:843–850. https://doi.org/10.1088/0960-1317/16/4/022

    Article  Google Scholar 

  3. Mastud S, Singh RK, Joshi SS (2012) Analysis of fabrication of arrayed micro-rods on tungsten carbide using reverse micro-EDM. Int J Manuf Technol Manag 26:176. https://doi.org/10.1504/IJMTM.2012.051430

    Article  Google Scholar 

  4. Singh AK, Patowari PK, Deshpande NV (2019) Analysis of micro-rods machined using reverse micro-EDM. J Brazilian Soc Mech Sci Eng 41:1–12. https://doi.org/10.1007/s40430-018-1519-4

    Article  Google Scholar 

  5. Lyubimov VV, Volgin VM, Gnidina IV, Salomatnikov MS (2018) The discharge channel formation and the mechanism of material removal during electrical discharge micromachining by nanosecond pulses. Procedia CIRP 68:325–329. https://doi.org/10.1016/j.procir.2017.12.072

    Article  Google Scholar 

  6. Shabgard M, Ahmadi R, Seyedzavvar M, Oliaei SNB (2013) Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process. Int J Mach Tools Manuf 65:79–87. https://doi.org/10.1016/j.ijmachtools.2012.10.004

    Article  Google Scholar 

  7. Ming W, Zhang Z, Wang S et al (2019) Comparative study of energy efficiency and environmental impact in magnetic field assisted and conventional electrical discharge machining. J Clean Prod 214:12–28. https://doi.org/10.1016/j.jclepro.2018.12.231

    Article  Google Scholar 

  8. Mastud S, Singh RK, Samuel J, Joshi SS (2011) Comparative analysis of the process mechanics in micro electrical discharge machining and reverse micro EDM. In: Proc ASME 2011 Int Manuf Sci Eng Conf June 13–17, 2011, Corvallis, Oregon, USA, pp 1–10

    Google Scholar 

  9. Kao CC, Shih AJ (2006) Sub-nanosecond monitoring of micro-hole electrical discharge machining pulses and modeling of discharge ringing. Int J Mach Tools Manuf 46:1996–2008. https://doi.org/10.1016/j.ijmachtools.2006.01.008

    Article  Google Scholar 

  10. Mahardika M, Mitsui K (2008) A new method for monitoring micro-electric discharge machining processes. Int J Mach Tools Manuf 48:446–458. https://doi.org/10.1016/j.ijmachtools.2007.08.023

    Article  Google Scholar 

  11. Liao YS, Chang TY, Chuang TJ (2008) An on-line monitoring system for a micro electrical discharge machining (micro-EDM) process. J Micromechanics Microengineering 18:035009. https://doi.org/10.1088/0960-1317/18/3/035009

    Article  Google Scholar 

  12. Nirala CK, Unune DR, Sankhla HK (2017) Virtual signal-based pulse discrimination in micro-electro-discharge machining. J Manuf Sci Eng 139:094501. https://doi.org/10.1115/1.4037108

    Article  Google Scholar 

  13. Yang F, Bellotti M, Hua H, Yang J, Qian J, Reynaerts D (2018) Experimental analysis of normal spark discharge voltage and current with a RC-type generator in micro-EDM. Int J Adv Manuf Technol 96:2963–2972. https://doi.org/10.1007/s00170-018-1813-4

    Article  Google Scholar 

  14. Mastud SA, Kothari NS, Singh RK et al (2014) Analysis of debris motion in vibration assisted reverse micro electrical discharge machining. In: Proceedings of the ASME 2014 International Manufacturing Science and Engineering Conference MSEC 2014

    Google Scholar 

  15. Newton TR (2008) Investigation of the effect of process parameters on the formation of recast layer in wire-EDM of investigation of the effect of process parameters on the formation of recast layer in wire-EDM of Inconel 718. Georgia Institute of Technology

  16. Roy T, Datta D, Balasubramaniam R (2019) Debris based discharge segregation in reverse micro EDM. Measurement:107433. https://doi.org/10.1016/j.measurement.2019.107433

    Article  Google Scholar 

  17. Xuyang C, Kai Z, Chunmei W et al (2015) A study on plasma channel expansion in micro-EDM. Mater Manuf Process 6914:150615134315006. https://doi.org/10.1080/10426914.2015.1059445

    Article  Google Scholar 

  18. IIT Kharagpur, NPTEL (2009) Module 9: electro discharge machining

    Google Scholar 

  19. Roy T, Datta D, Balasubramaniam R (2018) Numerical modelling, simulation and fabrication of 3-D hemi-spherical convex micro features using reverse micro EDM. J Manuf Process 32:344–356. https://doi.org/10.1016/j.jmapro.2018.02.018

    Article  Google Scholar 

Download references

Acknowledgements

The authors are very grateful to Prof. P. Pawar, SVERI Pandharpur, for permitting the use of computational software package.

Funding source

This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

Author information

Authors and Affiliations

  1. Homi Bhabha National Institute, Mumbai, 400094, India

    T. Roy & R. Balasubramaniam

  2. Department of Mechanical Engineering, Imperial College London, London, SW7 2AZ, UK

    T. Roy

  3. Bhabha Atomic Research Centre, Mumbai, 400085, India

    R. Balasubramaniam

Authors
  1. T. Roy
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. R. Balasubramaniam
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to T. Roy.

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

Roy, T., Balasubramaniam, R. Influence of ion-rich plasma discharge channel on unusually high discharging points in reverse micro electrical discharge machining. Int J Adv Manuf Technol 106, 4467–4475 (2020). https://doi.org/10.1007/s00170-020-04934-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-04934-6

Keywords

Search

Navigation