Abstract
EDM is the most popular unconventional machining process. The present technology of EDM consists of a pulsed or capacitive type power supply in which the pulsed type power supply is more popular and effective. The following essential component of an EDM is its servo mechanism, which controls the gap between the electrodes and maintains the gap voltage. A low machining speed, complex power supply, and servo mechanism increase the cost of machining and the maintenance cost of an EDM machine. To resolve the above issues from the EDM, a novel servo mechanism has been developed, which is simple in design and low in cost and has the capacity to use direct current as a power source. The current work elaborates a brief description of the novel servo mechanism and its feasibility analysis. Pure DC power is employed with the conjunction of Maglev lucidity to refine the shortcomings of conventional micro EDM. The novel technology addresses the prime concerns of conventional micro EDMs and deficiencies such as the delayed response of mechanical actuators and a servo mechanism. The novel technology uses the logical arrangement of permanent magnets and electromagnets to address inadequacies such as short circuiting and arcing. The work outlook is to establish the viability of the novel Maglev EDM by a comparison with a similar range of parameters. The results on the novel technology showed an improved material removal rate (MRR), which was in the range of 76.6 μgm/min, whereas the specific energy and surface roughness were 33.4 Joule/microgram and 4.3 μm, respectively, while machining commercially pure titanium.
Highlights
An electrical discharge machine (EDM) is the most popular and appropriate unconventional machining technique for machining hard-to-cut materials such as titanium and nickel-based alloys
The specific energy of the machining is calculated for the maglev EDM and compared with the existing literature, which showed that the specific energy is minimum in maglev EDM for CP-Ti
The novel Maglev EDM is explored by experiments on the CP-TI workpiece using the brass electrode
Summary
An electrical discharge machine (EDM) is the most popular and appropriate unconventional machining technique for machining hard-to-cut materials such as titanium and nickel-based alloys. Owing to the establishment of an electrical arena in the narrow gap between electrodes, the free electrons are subjected to electrostatic force and start to move from the cathode (tool) to the anode (workpiece) via the dielectric medium These free electrons gain energy and strike the molecules in the dielectric fluids. The influencing parameters in EDM can be categorized in two ways: electrical parameters such as discharge current, discharge voltage and pulse on time and nonelectrical parameters such as electrode gap, flushing medium, and tool life 20. The first ionization of the dielectric fluid is conducted, which helps to increase the discharge energy; a high required spark is produced in the second discharge zone for material removal. The proficiency of the novel machine is presented
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