Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process.

Abhimanyu Singh Mertiya,Aman Upadhyay,Ahmad Majdi Abdul-Rani,Catalin Iulian Pruncu,Pravin Pandit Harane,Kaustubh Nirwan,Deepak Rajendra Unune

doi:10.3390/ma14206192

Abstract

Difficulty in debris removal and the transport of fresh dielectric into discharge gap hinders the process performance of electrical discharge machining (EDM) process. Therefore, in this work, an economical low frequency vibration platform was developed to improve the performance of EDM through vibration assistance. The developed vibratory platform functions on an eccentric weight principle and generates a low frequency vibration in the range of 0–100 Hz. The performance of EDM was evaluated in terms of the average surface roughness (Ra), material removal rate (MRR), and tool wear rate (TWR) whilst varying the input machining parameters viz. the pulse-on-time (Ton), peak current (Ip), vibration frequency (VF), and tool rotational speed (TRS). The peak current was found to be the most significant parameter and contributed by 78.16%, 65.86%, and 59.52% to the Ra, MRR, and TWR, respectively. The low frequency work piece vibration contributed to an enhanced surface finish owing to an improved flushing at the discharge gap and debris removal. However, VF range below 100 Hz was not found to be suitable for the satisfactory improvement of the MRR and reduction of the TWR in an electrical discharge drilling operation at selected machining conditions.

Highlights

In the machining and forming industry, tool steels were designed to escalate production economic efficiency due to their improved mechanical properties including a high strength, wear resistance, hardness, and toughness
Owing to their excellent wear resistance and deep hardening features, tool steels in the AISI D2 category are extensively used in the mold and die industry for the production of blanking, cold-forming dies, stamping dies, slitters, punches and trim and rolling dies [1,2]
Studies have proved die-sink electrical discharge machining (EDM) to be technologically suitable for machining difficult-to-cut materials as it does not include work tool contact avoiding stresses, vibrations, and chatter as added advantages [4]

Summary

Introduction

In the machining and forming industry, tool steels were designed to escalate production economic efficiency due to their improved mechanical properties including a high strength, wear resistance, hardness, and toughness. The automobile industry, for example, has witnessed a rise in car manufacturing leading to an upsurge in the demand for tool steels. Other industries such as aerospace, transport, and precision industries have witnessed a rise in demand of tool steels. Owing to their excellent wear resistance and deep hardening features, tool steels in the AISI D2 category are extensively used in the mold and die industry for the production of blanking, cold-forming dies, stamping dies, slitters, punches and trim and rolling dies [1,2].

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Conclusion