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Investigation of machining performance in die-sinking electrical discharge machining of pentagonal micro-cavities using cylindrical electrode

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Abstract

The aim of the present article is to fabricate pentagonal micro-cavities and describe the influence of current on the machining performances. Machining of EN-24 alloy steel samples was performed in die-sinking electrical discharge machining (EDM) machine with varying values of current using polygon cycle approach. The machined pentagonal cavities were examined under optical microscope and scanning electron microscope (SEM) to evaluate machining performances in terms of corner error, white layer formation, surface crack distribution, and globule formation. It is found that as the value of current increases, there is more formation of white layer with non-uniform distribution of cracks and the thickness of white layer increased from 6.21 to 8.20 µm with increase in current. On the other hands, surface finish deteriorates when the current value rises. In addition to this, there is an enhancement in tool wear rate with increasing current. At the higher values of current, the spark energy increases which leads to greater melting and evaporation and production of smoke and bubbles on the dielectric surface. This study revealed that die-sinking EDM coupled with short electronic pulses and precise electrode movement is capable of producing microstructures under appropriate operating conditions.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Delhi Technological University, New Delhi, India

    Shrikant Vidya & Reeta Wattal

  2. Department of Mechanical Engineering, Indian Institute of Technology, New Delhi, India

    P Venkateswara Rao

  3. School of Mechanical Engineering, Galgotias University, Uttar Pradesh, Greater Noida, India

    Shrikant Vidya

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  1. Shrikant Vidya
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  2. Reeta Wattal
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  3. P Venkateswara Rao
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Correspondence to Shrikant Vidya.

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Technical Editor: Lincoln Cardoso Brandao.

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Vidya, S., Wattal, R. & Rao, P.V. Investigation of machining performance in die-sinking electrical discharge machining of pentagonal micro-cavities using cylindrical electrode. J Braz. Soc. Mech. Sci. Eng. 43, 288 (2021). https://doi.org/10.1007/s40430-021-03012-6

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  • DOI: https://doi.org/10.1007/s40430-021-03012-6

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