Recent Trends in Arc Machining Processes

Abstract

Arc machining methods are capable of contributing a high material removal rate (MRR) with less tool wear ratio (TWR) compared to other thermal material removal processes. The characteristic high thermal energy of arc plasma helps to easily erode the material. Depending on the source and nature of arc plasma formation, arc machining methods are categorized into plasma gas arc machining and electric discharge arc machining. While plasma arc drilling completely utilizes thermal energy, micro detonation striking arc machining (MDSAM) makes use of the micro detonation and subsequent shockwave induced by the generated plasma for material removal. At the same time, as electrical discharge machining (EDM) is a well-established non-conventional technique, research thrust is more directed towards combining arc machining with EDM. The characteristic bundled/bunched electrode in blast erosion arc machining (BEAM) process improves machining performance by effective debris removal. Along with BEAM, compound EDM arc machining methods such as moving arc high speed EDM milling, pulsed arc EDM milling and hybrid electrical discharge arc machining (HEDAM) offer promising performance. Such methods can be successfully employed for machining difficult-to-cut materials with applications demanding a faster rate of production. The future scope of research in the arc machining domain looks promising, specifically in the areas of online monitoring, intelligent machining and compound/hybrid machining.