Skip to main content
SpringerLink
Log in

Experimental and simulation study of the ED-milling flow field to improve its machining performance

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

Abstract

In electrical discharge milling (ED-milling), the flow field of the working medium plays an important role in the removal of discharge eroded particles from the discharge gap. In this work, a flow field model between the electrode and workpiece was established based on analysis of the moving path of the eroded particles in the discharge gap. The influence of the single-layer cutting thickness and electrode diameter on the flow field and machining performance was studied via simulations and experiments. Three kinds of new structure electrodes containing multiple holes were designed to improve the eroded particle removal efficiency. The flow field and machining performance of ED-milling with these new electrodes were studied via simulations and experiments. Through the design of multiple holes surrounding the electrode outer wall, the flushing flow field was more conducive to the removal process of the eroded particles. By adopting the newly designed electrode, the ED-milling machining efficiency was improved by 33%.

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

Similar content being viewed by others

Data availability

The authors confirm that the data supporting the findings of this study are available within the article.

References

  1. Ho KH, Newman ST (2003) State of the art electrical discharge machining (EDM). Int J Mach Tool Manu 43(13):1287–1300. https://doi.org/10.1016/s0890-6955(03)00162-7

    Article  Google Scholar 

  2. Muthuramalingam T, Mohan B (2015) A review on influence of electrical process parameters in EDM process. Arch Civil Mech Eng 15(1):87–94. https://doi.org/10.1016/j.acme.2014.02.009

    Article  Google Scholar 

  3. Ho KH, Newman ST, Rahimifard S, Allen RD (2004) State of the art in wire electrical discharge machining (WEDM). Int J Mach Tool Manu 44(12-13):1247–1259. https://doi.org/10.1016/j.ijmachtools.2004.04.017

    Article  Google Scholar 

  4. Fujimoto T, Okada A, Okamoto Y, Uno Y (2012) Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. Key Eng Mater 516:73–78. https://doi.org/10.4028/www.scientific.net/KEM.516.73

    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(3):531–538. https://doi.org/10.1016/j.jmatprotec.2013.10.015

    Article  Google Scholar 

  6. Pillai KVA, Hariharan P, Jafferson JM (2019) μED milling of Ti-6Al-4V using cryogenic-treated Wc tool and nano-graphene powder-mixed dielectricat different discharge energy regimes. Int J Adv Manuf Technol 102(9-12):2721–2743. https://doi.org/10.1007/s00170-019-03327-8

    Article  Google Scholar 

  7. Zhou T, Zhou C, Liang Z, Wang X (2017) Machining mechanism in tilt electrical discharge milling for lens mold. Int J Adv Manuf Technol 95(5-8):2747–2755. https://doi.org/10.1007/s00170-017-1408-5

    Article  Google Scholar 

  8. Chakraborty S, Dey V, Ghosh SK (2015) A review on the use of dielectric fluids and their effects in electrical discharge machining characteristics. Precis Eng 40:1–6. https://doi.org/10.1016/j.precisioneng.2014.11.003

    Article  Google Scholar 

  9. Shen Y, Liu Y, Sun W (2016) High-efficient dry hybrid machining of EDM and arc machining. Procedia CIRP 42:149–154. https://doi.org/10.1016/j.procir.2016.02.210

    Article  Google Scholar 

  10. Liu Y, Chang H, Zhang W, Ma F, Sha Z, Zhang S (2018) A Simulation study of debris removal process in ultrasonic vibration assisted electrical discharge machining (EDM) of deep holes (dagger). Micromachines 9(8). https://doi.org/10.3390/mi9080378

  11. Mullya S, Karthikeyan G, Ganachari V (2020) An investigation into performance of electric discharge milling using slotted tools. J Mech Sci Technol 34(6):2525–2533. https://doi.org/10.1007/s12206-020-0528-2

    Article  Google Scholar 

  12. Wang X, Shen Y (2019) High-speed EDM milling with in-gas and outside-liquid electrode flushing techniques. Int J Adv Manuf Technol 104(5-8):3191–3198. https://doi.org/10.1007/s00170-019-04242-8

    Article  Google Scholar 

  13. Okada A, Uno Y, Onoda S, Habib S (2009) Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf. CIRP Ann 58(1):209–212. https://doi.org/10.1016/j.cirp.2009.03.003

    Article  Google Scholar 

  14. Wang J, Han F (2014) Simulation model of debris and bubble movement in electrode jump of electrical discharge machining. Int J Adv Manuf Technol 74(5-8):591–598. https://doi.org/10.1007/s00170-014-6008-z

    Article  Google Scholar 

  15. Chang WJ, Xi YY, Li HW (2020) Simulation of gap flow field in EDM process uesd oil-in-water working fluid. Key Eng Mater 841:232–237. https://doi.org/10.4028/www.scientific.net/KEM.841.232

    Article  Google Scholar 

  16. Feng G, Yang X, Chi G (2018) Experimental and simulation study on micro hole machining in EDM with high-speed tool electrode rotation. Int J Adv Manuf Technol 101(1-4):367–375. https://doi.org/10.1007/s00170-018-2917-6

    Article  Google Scholar 

  17. Wang YQ, Bai JC, Guo YF, Huang H (2011) Investigation of the effects of dielectric inlet pressure in inner jetted dielectric EDM milling. Adv Mater Res 189-193:125–128. https://doi.org/10.4028/www.scientific.net/AMR.189-193.125

    Article  Google Scholar 

  18. 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 Tool Manu 65:79–87. https://doi.org/10.1016/j.ijmachtools.2012.10.004

    Article  Google Scholar 

  19. Liao YS, Wu PS, Liang FY (2013) Study of debris exclusion effect in linear motor equipped die-sinking EDM process. Procedia CIRP 6:123–128. https://doi.org/10.1016/j.procir.2013.03.058

    Article  Google Scholar 

  20. Wang Z, Tong H, Li Y, Li C (2018) Dielectric flushing optimization of fast hole EDM drilling based on debris status analysis. Int J Adv Manuf Technol 97(5-8):2409–2417. https://doi.org/10.1007/s00170-018-2141-4

    Article  Google Scholar 

  21. Kunieda M, Kitamura T (2018) Observation of difference of EDM gap phenomena in water and oil using transparent electrode. Procedia CIRP 68:342–346. https://doi.org/10.1016/j.procir.2017.12.065

    Article  Google Scholar 

Download references

Code availability

Not applicable.

Funding

This research is supported by the Fundamental Research Funds for the Central Universities of China (grant no. 2572017BB06).

Author information

Authors and Affiliations

  1. School of Engineering and Technology, Northeast Forestry University, Harbin, China

    Chengbo Guo & Shufa Sun

  2. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, China

    Shichun Di & Dongbo Wei

Authors
  1. Chengbo Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shufa Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shichun Di
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Dongbo Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chengbo Guo.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

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

Guo, C., Sun, S., Di, S. et al. Experimental and simulation study of the ED-milling flow field to improve its machining performance. Int J Adv Manuf Technol 113, 2513–2522 (2021). https://doi.org/10.1007/s00170-021-06804-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06804-1

Keywords

Search

Navigation