Skip to main content
SpringerLink
Log in

Mechanism study of micro-electrical discharge drilling method during micro-dimpling

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

This paper reports the cutting mechanism in micro-electrical discharge drilling (uEDD) during a micro-dimpling process. A combination of fundamental micro-drilling and micro-electrical discharge machining (uEDM) is considered the main mechanism in the uEDD process. First, the cutting force in micro-drilling was modeled on a chisel and lip section based on a mechanistic model of the oblique cutting. Second, the model of the uEDM was also included based on uniform heat flux. Experiments of a micro-dimple were carried out on a titanium alloy (Ti6AI4V) to confirm the model validity. The validation confirms that the proposed cutting force model can be applied to predict the thrust force during micro-dimpling under uEDD. In addition, a micro-dimple morphology is also discussed.

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

Abbreviations

R D :

Maximum radius of micro-crater

t dis :

Discharge time of plasma spark

q 0 :

Heat flux density

Q a :

Heat absorption to the anode

Q D :

Heat flow rate

ζ:

Percentage

E D :

Discharge energy

C D :

Discharge capacitance

V D :

Discharge voltage

α D :

Diffusivity

λk :

Thermal conductivity

C p :

Specific heat

ρ:

Density

ierf :

Integral complementary error function

T(z):

Temperature as a function of micro-crater depth

T s :

Johnson-Cook shear stress

A,B,C,n,m :

Johnson-Cook material constant

Tr, Tm :

Room temperature, melting temperature

Y d :

Velocity angle

i :

Oblique angle

θ:

Angle between radius r and y-axis

K t :

Taper angle of micro-drill tool

Ψc :

Chisel edge angle

βh_o :

Local helix angle on the lip

βh :

Helix angle of micro-drill tool

βn :

Normal friction angle

βa :

Average friction angle in orthogonal cutting

αf, αn :

Effective rake angle, normal rake angle

ϕn :

Merchant shear angle

φIM :

Immersion angle

R :

Radius of micro-drill

r :

Radius from lip to z-axis

Ktc, Kfc, Krc :

Cutting coefficient in oblique cutting

Kte, Kfe, Kre :

Cutting edge constant

dFt, dFf, dFr :

Elemental cutting forces

F z,lip :

Total thrust force on the two lip edges

F z,chisel :

Chisel thrust force

F z,total :

Total thrust force

Fz,thrust :

Thrust force in sinusoidal form

Fx,Fy :

Total cutting force in x- and y- direction

A chisel :

Chisel area

H vickers :

Vickers hardness in MPa

f d :

Feed rate

w :

Half of total chisel width

h :

Chip thickness on the lip edge

db :

Elemental width of chip on the lip edge

dz :

Elemental width of elevation z

dA :

Elemental cutting area

References

  1. I. Basso, M. F. Batista, R. G. Jasinevicius, J. C. C. Rubio and A. R. Rodrigues, Micro drilling of carbon fiber reinforced polymer, Composite Structures, 228 (2019) 111312.

    Article  Google Scholar 

  2. T. Tamura, R. Akiyama, R. I. Tanaka, H. Kawamoto and S. Umezu, Groove fabrication on surface of soft gelatin gel utilizing micro-electrical discharge machining (Micro-EDM), Journal of Food Engineering, 277 (2020) 109919.

    Article  Google Scholar 

  3. R. Kurniawan and T. J. Ko, Friction reduction on cylindrical surfaces by texturing with a piezoelectric actuated tool holder, Int. J. Precis. Eng. Manuf., 16 (5) (2015) 861–868.

    Article  Google Scholar 

  4. A. Greco, S. Raphaelson, K. Ehmann, Q. J. Wang and C. Lin, Surface texturing of tribological interface using the vibrome-chanical texturing method, Journal of Manufacturing Science and Engineering, 131 (6) (2009) 1–8.

    Article  Google Scholar 

  5. T. Matsumura and S. Takahashi, Micro dimple milling on cylinder surfaces, J. Manuf. Process., 14 (2) (2012) 135–140.

    Article  Google Scholar 

  6. R. Kurniawan, G. Kiswanto and T. J. Ko, Micro-dimple pattern process and orthogonal cutting force analysis of elliptical vibration texturing, Int. J. Mach. Tools Manuf, 106 (2016) 127–140.

    Article  Google Scholar 

  7. S. T. Jung, S. T. Kumaran, C. P. Li, R. Kurniawan and T. J. Ko, Performance evaluation of micro-dimple formation on a T-6AI-4V alloy by using electrical discharge drilling, Journal of Mechanical Science and Technology, 32 (9) (2018) 4365–4372.

    Article  Google Scholar 

  8. T. Pratap and K. Patra, Mechanical micro-texturing of Ti-6AI-4V surfaces for improved wettability and bio-tribological performances, Surf. Coatings Technol., 349 (2018) 71–81.

    Article  Google Scholar 

  9. P. J. Arrazola, A. Garay, L. M. Iriarte, M. Armendia, S. Marya and F. Le Maitre, Machinability of titanium alloys (Ti6AI4V and Ti555. 3), Journal of Material Processing Technology, 209 (5) (2009) 2223–2230.

    Article  Google Scholar 

  10. S. I. Jaffery and P. T. Mativenga, Assessment of the machinability of Ti-6AI-4V alloy using the wear map approach, Int. J. Adv. Manuf. Technol., 40 (7-8) (2009) 687–696.

    Article  Google Scholar 

  11. A. Hasçalikand U. Çaydas, Electrical discharge machining of titanium alloy (Ti-6AI-4V), Appl. Surf. Sci., 253 (22) (2007) 9007–9016.

    Article  Google Scholar 

  12. Y. B. Guo and R. Caslaru, Fabrication and characterization of micro dent arrays produced by laser shock peening on titanium Ti-6AI-4V surfaces, J. Mater. Process. Technol., 211 (4) (2011) 729–736.

    Article  Google Scholar 

  13. M. Gostimirovic, V. Pucovsky, M. Sekulic, M. Radovanovic and M. Madic, Evolutionary multi-objective optimization of energy efficiency in electrical discharge machining, Journal of Mechanical Science and Technology, 32 (10) (2018) 4775–4785.

    Article  Google Scholar 

  14. Z. Zhao, Y. Wang, Z. Wang and J. Liu, Thermal analysis for the large precision EDM machine tool considering the spark energy during long-time processing, Journal of Mechanical Science and Technology, 33 (2) (2019) 773–782.

    Article  Google Scholar 

  15. Z. Zhao, J. Zhang, Y. Wang, Z. Wang, J. Liu and C. Quan, Dynamic thermal behavior and thermal error prediction of spindle due to periodic jump motions in a large precision die sinking EDM machine, Journal of Mechanical Science and Technology, 33 (7) (2019) 3397–3405.

    Article  Google Scholar 

  16. J. Sträsky, M. Janecek, P. Harcuba, M. Bukovina and L. Wagner, The effect of microstructure on fatigue performance of Ti-6AI-4V alloy after EDM surface treatment for application in orthopaedics, Journal of the Mechanical Behavior of Biomedical Materials, 4 (8) (2011) 1955–1962.

    Article  Google Scholar 

  17. D. T. Phan, S. S. Dimov, S. Bigot, A. Ivanov and K. Popov, Micro-EDM—Recent developments and research issues, Journal Materials Processing Technology, 149 (1-3) (2004).

    Google Scholar 

  18. Y. S. Wong, M. Rahman, H. S. Lim, H. Han and N. Ravi, Investigation of micro-EDM material removal characteristics using single RC-pulse discharges, Journal of Materials Processing Technology, 140 (1–3) (2003) 303–307.

    Article  Google Scholar 

  19. D. D. DiBitonto, P. T. Eubank, M. R. Patel and M. A. Barrufet, Theoretical models of the electrical discharge machining process. I. A. simple cathode erosion model, Journal of Applied Physics, 66 (9) (1989) 4095–4103.

    Article  Google Scholar 

  20. M. R. Patel, M. A. Barrufet, P. T. Eubank and D. D. DiBitonto, Theoretical models of the electrical discharge machining process. II. The anode erosion model, Journal of Applied Physics, 66 (9) (1989) 4104–4111.

    Article  Google Scholar 

  21. S. H. Yeo, W. Kurnia and P. C. Tan, Electro-thermal modelling of anode and cathode in micro-EDM, J. Phys. D. Appl. Phys., 40 (8) (2007) 2513–2521.

    Article  Google Scholar 

  22. P. Govindan and S. S. Joshi, Experimental characterization of material removal in dry electrical discharge drilling, Int. J. Mach. Tools Manuf, 50 (5) (2010) 431–443.

    Article  Google Scholar 

  23. K. Y. Song, M. S. Park and C. N. Chu, Micro electrical discharge drilling of tungsten carbide using deionized water, Journal of Micromechanics and Microengineering, 19 (4) (2009).

    Google Scholar 

  24. S. Plaza, J. A. Sanchez, E. Perez, R. Gil, B. Izquierdo, N. Ortega and I. Pombo, Experimental study on micro EDM-drilling of Ti6AI4V using helical electrode, Precision Engineering, 38 (4) (2014) 821–827.

    Article  Google Scholar 

  25. M. Ay, U. Çaydas and A. Hasçalik, Optimization of micro-EDM drilling of inconel 718 superalloy, Int. J. Adv. Manuf. Technol., 66 (5–8) (2013) 1015–1023.

    Article  Google Scholar 

  26. E. Yun, K. Lee and S. Lee, Improvement of high-temperature hardness of (TiC, TiB)/Ti-6AI-4V surface composites fabricated by high-energy electron-beam irradiation, Surf. Coatings Technol., 184 (1) (2004) 74–83.

    Article  MathSciNet  Google Scholar 

  27. Y. Altintas, Manufacturing Automation-metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, 2nd ed, Cambridge University Press, United States (2012).

    Google Scholar 

  28. A. Moufki, D. Dudzinski and G. Le Coz, Prediction of cutting forces from an analytical model of oblique cutting, application to peripheral milling of Ti-6AI-4V alloy, Int. J. Adv. Manuf. Technol., 81 (1–4) (2015) 615–626.

    Article  Google Scholar 

  29. M. Shatla and T. Altan, Analytical modeling of drilling and ball end milling, J. Mater. Process. Technol., 98 (1) (2000) 125–133.

    Article  Google Scholar 

  30. R. Kurniawan and T. J. Ko, Cutting force model in micro-dimple pattern process using two-frequency elliptical vibration texturing (TFEVT) method, Int. J. Precis. Eng. Manuf, 20 (1) (2019) 1–11.

    Article  Google Scholar 

  31. M. Kunieda, M. Yoshida and N. Taniguchi, Electrical discharge machining in gas, CIRP Ann. - Manuf. Technol., 46 (1) (1997) 143–146.

    Article  Google Scholar 

  32. B. Shao and K. P. Rajurkar, Modelling of the crater formation in micro-EDM, Procedia CIRP, 33 (2015) 376–381.

    Article  Google Scholar 

  33. R. Kurniawan, S. T. Kumaran, V. A. Prabu, Y. Zhen, K. M. Park, Y. I. Kwak and T. J. Ko, Measurement of burr removal rate and analysis of machining parameters in ultrasonic assisted dry EDM (US-EDM) for deburring drilled holes in CFRP composite, Measurement, 10 (2017) 98–115.

    Article  Google Scholar 

  34. M. Y. Kim, C. P. Li, R. Kurniawan, S. T. Jung and T. J. Ko, Experimental investigation of burr reduction during EDM end-milling hybrid process, Journal of Mechanical Science and Technology, 33 (6) (2019) 2847–2853.

    Article  Google Scholar 

  35. H. T. Lee and T. Y. Tai, Relationship between EDM parameters and surface crack formation, J. Mater. Process. Technol., 142 (3) (2003) 676–683.

    Article  Google Scholar 

Download references

Acknowledgments

This research was supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Science, ICT, and Future Planning [Grant Number NRF-2020R1A2B5B02001755]. This work was also supported by the 2019 Yeungnam University Research Grant.

Author information

Authors and Affiliations

  1. Pohang Accelerator Laboratory, Pohang University of Science and Technology, Pohang-Si, 37673, Korea

    Sang Tae Jung

  2. Precision Machining Laboratory, Department of Mechanical Engineering, Yeungnam University, Gyeongsan-Si, 38541, Korea

    Rendi Kurniawan, In Jun Yoon & Tae Jo Ko

  3. Faculty of Mechanical Engineering, Kalasalingam University, Tamil Nadu, Krishnankoil, 626-126, India

    S. Thirumalai Kumaran

Authors
  1. Sang Tae Jung
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Rendi Kurniawan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. S. Thirumalai Kumaran
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. In Jun Yoon
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Tae Jo Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Rendi Kurniawan.

Additional information

Recommended by Editor Hyung Wook Park

Sang Tae Jung is a Senior Researcher at Pohang University of Science and Technology. He received his bachelor degree from Dongguk University, South Korea. He received his M.S. Eng. and Ph.D. degrees in Mechanical Engineering from Yeungnam University, South Korea. His research interests include nontraditional machining, micro stereo-lithography process using UV lamp, and micro electrical discharge drilling.

Rendi Kurniawan is an Assistant Professor in Mechanical Engineering at Yeungnam University, South Korea. He received bachelor degree from Univer-sitas Indonesia, Indonesia. His M.S. Eng. and Ph.D. degrees in Mechanical Engineering were obtained from Yeungnam University, South Korea. His research interests are surface texturing, tribology, micro-dimple fabrication, ultrasonic transducer, elliptical vibration texturing, and micro electrical discharge drilling.

Tae Jo Ko is a Professor in Mechanical Engineering at Yeungnam University, South Korea. He received his Ph.D. in Mechanical Engineering from POSTECH, South Korea. His research interests include micro-cutting process, non-traditional machining, surface texturing, bio-machining, hybrid EDM-milling process, textured surface on end-mill, deburring process of CFRP composite, and CFRP drilling.

S. Thirumalai Kumaran is currently an Associated Professor at Kalasalingam University, Tamil Nadu, India. He received M.Tech degree from Government College of Technology, Tamil Nadu, India. He received Ph.D. degree in Mechanical Engineering from Kalasalingam University, Tamil Nadu, India. His research interests include tribological studies, surface modification, machining studies, cryogenics and material characterization.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jung, S.T., Kurniawan, R., Kumaran, S.T. et al. Mechanism study of micro-electrical discharge drilling method during micro-dimpling. J Mech Sci Technol 34, 2549–2559 (2020). https://doi.org/10.1007/s12206-020-0530-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-020-0530-8

Keywords

Search

Navigation