Đánh giá ảnh hưởng của các thông số quá trình điện trong quy trình EDM

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Review A review on inﬂuence of electrical process parameters in EDM process

T. Muthuramalingam a,*, B. Mohan b

a Department of Mechatronics Engineering, SRM University, Kattankulathur, India b Department of Mechanical Engineering, CEG Campus, Anna University, Chennai, India

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Article history:

Since the thermal energy produced in electrical discharge machining process is due to the

Received 12 July 2013

Accepted 16 February 2014

Available online 14 April 2014

applied electrical energy, it is very important to enhance the electrical process parameters to improve the process efﬁciency. The present study discusses about having an overview of the EDM process, modeling of process parameters, and inﬂuence of process parameters such as input electrical variables, pulse shape, and discharge energy on performance measures such

as material removal rate, surface roughness and electrode wear rate. This study also

Keywords:

discusses about controlling the electrical process parameters, and empirical relationships

EDM

EWR

Discharge

between process parameters and optimization of process parameters in EDM process. From the review results, it has been observed that the efﬁcacy of the machining process can be improved by electrical process parameters, and only less attention has been given for

MRR

enhancing such parameters.

Surface

1. Introduction

into positive

Electrical discharge machining (EDM), otherwise known as thermal erosion process, is one of the non-conventional machining processes, where tool and workpiece do not come into contact with each other during the machining process. The progression of events constituting the process of material erosion from the work surfaces by an electrical discharge machining can be explained in the following way. If an appropriate voltage is developed across the tool electrode (normally cathode) and the workpiece (normally anode), the breakdown of dielectric medium between them happens due to

ﬁeld. Owing to the electric the growth of a strong electrostatic ﬁeld, electrons are emitted from the cathode toward the anode on the electrode surfaces having the shortest distance between them. These electrons impinge on the dielectric molecules of ﬂuid mole- the insulating medium, breaking these dielectric ions and electrons. These secondary cules electrons travel along on the same ionization path. This event ﬁeld strength across the work causes an increase in the electric surfaces and liberates a large number of electrons. It creates an ionized column in the shortest spark gap between the tool electrode and the workpiece, thereby decreasing the resistance ﬂuid column and causing an electrical discharge in the of the shortest distance point between the tool and the workpiece. The

* Corresponding author. Tel.: +91 9994872013; fax: +91 4422232403.

E-mail addresses: muthu1060@gmail.com, muthu_456@yahoo.com (T. Muthuramalingam), mohan@mitindia.edu (B. Mohan).

http://dx.doi.org/10.1016/j.acme.2014.02.009 1644-9665/#

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88 Enhancing the performance of pulse

3. generator

improve the performance measures

Since the electrical energy is supplied to the EDM process informing the DC pulses, the pulse generator needs to be in the upgraded to machining process. The lower energy pulses enhance the ﬁnish of the workpiece whereas the higher energy surface pulses improve the material removal rate.

–

Fig. 1

Basic mechanism involved in EDM.

Jahan et al. conducted a detailed experimental investiga- ﬁnd out the inﬂuence of major operating parameters on tion to surface quality of tungsten carbide with both transistor and RC-type generators in EDM process [5]. It has been proved that ﬁnish RC pulse generator has produced a smoother surface than the transistor pulse generator due to its lower discharge energy distribution over the surface of tungsten carbide. Han et al. designed and developed a modiﬁed transistor pulse generator with pulse frequency of 1 MHz to produce higher material removal rate than the RC pulse generator in the electrical discharge machining process [6]. They found that the transistor pulse generator has provided two or three times higher machining speed than the conventional RC pulse generator while machining tungsten workpiece with brass electrode.

A pulse generator based on

enormous thermal energy melts and vaporizes the material from the workpiece, which creates a small crater over the work surface. There happened a collapse of the ionized column with the termination of the electrical energy by means of the ﬂuid occupies switching circuit and then surrounding dielectric ﬂushing process. its place. The melted debris is removed by the The conduction of dielectric medium can be determined by the current, duration and pulse energy [1]. Fig. 1 explains the formation of ionized column in the shortest distance of work surfaces using the EDM process [1].

2. State of art in EDM process

ﬁxed pulse width modulation has been developed by Yan and Liu to generate the high frequency 4.4 MHz and short duration pulse control signals to reduce surface roughness of the workpiece tungsten carbide in the EDM process [7]. From the experimental results, it has been observed that the very low discharge energy pulse applied between tool and electrode has improved the surface quality of workpiece during the machining process. Yan and Chiang discussed about the development and application of a new power supply in wire electrical discharge machining process [8].

ﬁnish

than

A transistor-controlled power supply composed of a low energy discharge circuit has been designed to provide the functions of high frequency and lower energy pulse control. The experimental results have shown that the low peak ﬁnish in EDM current has been resulted in better surface process. Muthuramalingam and Mohan discussed about effect of uniform distribution for improving the surface quality using iso current pulse generator in EDM process [9]. Fig. 2 shows the surface quality of workpiece made by three different pulse generators. It has been observed that the iso current pulse generator could produce better surface the conventional pulse generators such as RC pulse generator and transistor pulse generator.

Han et al. designed and developed a new transistor type pulse generator with high frequency response to produce higher erosion rate of the workpiece in the electrical discharge machining process [10]. From the experimental results, it has been observed that the modiﬁed transistor pulse generator has produced 24 times higher material removal rate than the RC pulse generator in the EDM process. Yan and Lai presented the ﬁne-ﬁnish power supply with high frequen- development of a cy in EDM process [11]. This power supply has been composed with full bridge circuit, two snubber circuits and a pulse control circuit. It has been found that the proposed power supply has

Since the electrical discharge machining process is of with non-linear nature, it requires a lot of improvements on it. Many authors have discussed about the research works for improving process efﬁciency of the EDM process. The funda- mentals of EDM process mechanism and research works carried out from the inception to the development of the die- sinking EDM process within the past decade have been discussed by Ho and Newman [2]. It has been reported and discussed about the EDM researches relating to improve the process performance measures, optimizing the process vari- ables, and monitoring and control of the sparking process. Abbas et al. presented the recent research trends to improve the performance characteristics involved in all the aspects of electrical discharge machining process. They discussed about the need for controlling the process parameters to enhance the machining process efﬁciency of the EDM process [3]. The development of new technologies for improving the surface quality of workpiece is a signiﬁcant research area in EDM process. Kumar et al. presented a review on the phenomenon of surface modiﬁcation by EDM and future trends of its applications [4]. It has been observed that most of the research works concentrated on surface modiﬁcation using the powder mixed dielectric medium in EDM process. The study of the impact of the electrical process parameters on surface modiﬁcation of the workpiece has been taken up by very few researchers.

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–

Fig. 2

Surface topography of machined surface using different pulse generators.

carbide and SKD die steel with electrolytic copper tool electrode in the EDM process has been investigated by Tsai and Lu [15]. From the experimental results, it has been found that the material removal rate and tool wear rate have been affected by the energy density. Muthuramalingam and Mohan discussed about inﬂuence of discharge current impulse on the performance measures in EDM process [16].

produced lower discharge energy and thus contributed to lower surface roughness. Muthuramalingam and Mohan developed a semiconductor based pulse switching circuit to ﬁnishing level produce lower energy discharge pulses during of the process for enhancing the EDM performance character- istics [12]. Casanueva et al. attempted to establish a new EDM impulse generator based on high frequency switched DC-to- DC series-parallel resonant converter [13]. It has been claimed that the capacitance effect has affected the overall impedance of the EDM arrangement and thus altered the machining characteristics of EDM process.

Inﬂuence of pulse shape on performance

4. measures

Studying the variation of the EDM process response char- acteristics due to change in shape of the generated pulse is one of the research aspects in the EDM process. The discharge pulse shape affects the average spark energy which is delivered on the surface. Since the machining characteristics in EDM process depend on the electrical energy, the pulse shape which has an effect on the machining characteristics such as material removal rate, surface quality and electrode wear rate as shown in Fig. 3.

The effects of the voltage excitation of the pre-ignition spark pulse on the performance measures such as material removal rate, electrode wear rate and average surface roughness have been discussed by Ghoreishi and Tabari [14]. Based on the results, it is clear that applying voltage excitation of the pulse has produced an effective pulse which in turn increased material erosion and surface quality. The inﬂuence of the current impulse on machining tungsten

Son et al. investigated the inﬂuences of electrical pulse condition on the machining characteristics in the EDM process [17]. It has been found that the duration of pulse considerably affects the machining characteristics such as material removal rate, tool wear rate and surface accuracy. It has also been realized that the shorter EDM pulse could be efﬁcient to make a precision part. Liu et al. described the inﬂuence of the EDM discharge pulse shape on the machining characteristics such –TiN [18]. The surface as material removal mechanism of Si3N4 texture of machined workpiece has been investigated with different form of discharge pulse such as relaxation and iso current pulse. It has been proved that uniform discharge energy has produced good surface topography. Janardhan and Samuel analyzed the effect of machining parameters on material removal rate and average surface roughness using the pulse train data acquired at the spark gap with the help of MATLAB software package [19]. It has been observed that the material erosion rate has been increased with decrease in the pulse off time in EDM process. Yeo et al. proposed a new pulse discriminating technique for monitoring electrical discharge machining process [20]. This system has employed the current it has been pulse as the main detecting parameter as considered to be a better representation of the spark energy inside the plasma channel as compared to the voltage. There ﬁnish for an should be less arcing effect to enhance the surface ideal EDM process. Muthuramalingam and Mohan discussed and proved that the uniform duration pulse shape for the discharging phenomenon in EDM process has improved the surface quality of the workpiece with less arcing effect [21].

Inﬂuence of electrical process parameters

5. on performance measures

–

Relation between pulse shape and machining

Fig. 3 characteristics in EDM process.

There are many research works that have been conducted to ﬁnd the inﬂuence of process parameters especially electrical

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response parameters in the die-sinking EDM process using response surface methodology. It has been concluded that the lower values of the current intensity and the machining time ﬁnish. The use have to be used in order to obtain a good surface of the dimensional analysis for investigating the effects of the electrical and the physical parameters on the material removal rate of a die-sinking EDM process has been described by Yahya and Manning [28]. From the experimental results, it has been found that the material removal rate has been increased with discharge current, gap voltage and pulse on time.

–

Fig. 4

SEM images of surface using EDM process.

process parameters on EDM process. Most of the research works reveal that the discharge current and machining time have the most inﬂuencing nature on the EDM performance measures. Fig. 4 shows the SEM images of EDM surface while machining AISI 202 stainless steel with tungsten carbide tool electrode.

Huang et al. made an attempt to unveil the inﬂuence of the process parameters on the machining performances in the EDM process [29]. It has been found that the pulse on time and spark gap have the most signiﬁcant nature to affect the performance measures such as surface roughness and white layer depth using numerical analysis. Kuppan et al. reported about the experimental investigation of small deep hole drilling of Inconel 718 with electrolytic copper tool electrode using the electrical discharge machining process [30]. The experimental results have shown that the material removal rate has been increased with the increase in the peak current and duty factor. Patel et al. –Al investigated the feasibility of fabricating micro holes in SiCp composites using electrical discharge machining with a rotary tube electrode [31]. They have investigated the material removal rate, electrode wear rate and hole tapper as the responses for the study. The experimental results have revealed that pulse on duration has signiﬁcantly affected the response characteristics involved in EDM process. Pelicer et al. focused on investigating inﬂuence of EDM process parameters and electrode the geometry on feature micro accuracy on tool steel for mold fabrication purposes [32]. A set of designed experiments with varying process parameters such as pulse current, open voltage and pulse duration have been carried out in H13 steel using different shaped copper electrodes. It has been concluded that the triangular shaped electrode would produce highly inefﬁ- cient output, since the fast wearing nature of the electrode edges. Wang et al. carried out a series of experiments to investigate the impacts of machining polarity, electrode rotation speed and nominal capacitance on the material removal rate and tool wear rate with poly crystalline diamond It has been demonstrated that favorable machining [33]. performance of EDM process on the workpiece could be achieved in tool with negative polarity as compared to the positive polarity.

Gostimirovic et al. investigated the effects of electrical the performances of die-sinking process parameters on electrical discharge machining process with RC pulse generator while machining manganese-vanadium tool steel workpiece using graphite tool electrode. They found that the discharge current and pulse duration have highly inﬂuenced the material removal rate of the EDM process [22]. Mohan et al. analyzed the effect of EDM process parameters such as electrode material, polarity, pulse duration, current and rotation of the electrode on the material removal rate, tool wear rate and surface roughness [23]. It has been found that the material removal rate and tool wear rate have been increased with the discharge current during machining process. Nowicki et al. analyzed the effects individual electrical discharge on the crater volume of the workpiece in EDM process [24]. They found that the crater surface exhibits strong interaction with the electrical discharge spark. Mohan et al. investigated the surface roughness of the SiC/6025Al composite surface using electrical discharge ma- chining process with brass as the tool electrode [25]. From the experimental results, it has been observed that increasing peak current has resulted in higher surface roughness during the machining process.

Seo et al. discussed about

Tosun et al. presented an investigation on the effect and optimization of machining parameters on kerf and material removal rate in wire EDM process with Taguchi method [34]. The experimental studies have been conducted under varying pulse ﬂushing pressure with duration, gap voltage, wire speed and AISI 4140 steel as workpiece material. Based on the ANOVA method, the high effective parameter on both kerf and material removal rate has been found as pulse duration. Ji et al. presented a new process of machining SiC ceramics using electrical discharge milling process [35]. The effects of tool polarity, pulse duration, voltage and peak current on the process performances such as material removal rate, electrode wear rate and surface roughness have been investigated. It has been found that the negative polarity tool electrode with longer pulse duration has produced high material removal rate and surface roughness. Rebelo et al. presented an experimental study on the effect of

the drilling process of a functionally graded 15–35 vol.% of silicon carbide particulate reinforced Al359 metal matrix composite by electrical discharge machining process to assess the machinability and workpiece quality [26]. It has been observed that the peak current and pulse on time have increased the material removal rate. It has also been reported that increase in percentage SiC particles has increased the material removal rate and electrode wear rate. Puertas et al. carried out a study on the inﬂuence of the factors of current intensity, pulse time and duty cycle over the material removal rate, surface quality and electrode wear rate [27]. They modeled the relationship between the input parameters and

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increased with

electric discharge machining parameters on material removal rate and surface quality with high strength copper–beryllium alloys [36]. They found that the plasma diameter has been decreased with pulse duration and discharge current during the machining process.

measurement of arc plasma diameter in EDM [44]. They found increasing that the arc plasma has been discharge current. It has been veriﬁed that crater diameter and depth decrease with increasing gap width due to the increased plasma diameter. The arc plasma diameter has been increased with increasing spark gap and thus clariﬁed the reason for ﬁnish with lower material removal rate and smoother surface longer spark gap. Wong et al. developed a single spark pulse generator using resistance–capacitance arrangement to study the erosion characteristics in the EDM process from the crater size [45].

[39].

–TiC with EDM process

–SiCw

Yu et al. examined the use of electrical discharge machin- ing on machining poly-crystalline silicon [37]. The effects of different WEDM process parameters on machining character- istics have been explored. From the experimental results, it has been indicated that the pulse on time has the great inﬂuence on the cutting speed in Wire EDM process. Batish investigated the effect of process parameters and et al. mechanism of material deposition in electric discharge machining on surface properties of EN31, H11 and high carbon high chromium die steel materials [38]. It has been discussed about material transfer mechanism involved in EDM process. It has been found that die steels have been machined effectively with copper tool electrode using EDM process. Patel et al. presented a detailed experimental investigation of integrity and machining characteristics such as surface material removal mechanisms of advanced ceramic compos- ite Al2O3 It has been concluded that the surface roughness and material removal rate have been increased with pulse duration in EDM process.

Inﬂuence of discharge energy on

6. performance measures

The volume and size of the craters have been found to be more consistent at lower energy discharge sparks than the higher energy discharge sparks. The higher energy pulse leads to the micro surface crack on the work surface. Guu et al. aimed to investigate the machining characteristics of manga- nese–zinc ferrite magnetic materials using electrical discharge machining process [46]. The experimental results have indicated that the morphology of debris revealed the mecha- nism of material removal. It has been observed that the better machined surface has been obtained by setting process parameters at low pulse energy. Nowicki et al. made an attempt to machine superﬁcial layer of the workpiece using brush EDM process by modifying the spark energy [47]. The theoretical modeling of the EDM process based upon the heat transfer equations has been established by Singh [48]. In the study, the input energy equation has been developed as a function of pulse duration, current, polarity of electrode and properties of the workpiece and tool electrodes. This model has been helpful to calculate the optimal process parameters for obtaining optimum discharge energy.

7. Monitoring and control of the EDM process

In view of the fact that when the discharge energy is converted into the thermal energy to melt and vaporize the material in EDM process, it is unavoidable to discuss the inﬂuence of the pulse energy on the machining characteristics in such a process.

ﬁne surface

An adaptive control system

lower

inﬂuence of energy

investigated the

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The EDM process parameters have to be monitored during the machining process so that the controlling of those parameters can be done to obtain the required response parameters. The main action of monitoring and controlling the process is to observe and measure process parameters to reduce the deviation of performance measures from the expected level. for process monitoring, identiﬁcation and control in the wire electrical discharge machining process has been developed by Yan [49]. It has been realized that the wire breaking has been controlled by adjustment of pulse interval of each pulse cycle of supply. Caydas et al. developed an adaptive neuro-fuzzy inference system model for the prediction of the surface roughness of machined surface using wire EDM process as a function of process parameters such as open circuit voltage, pulse duration and wire feed rate [50]. From the experimental results, it has been found that the proposed control system has improved the surface quality in EDM process.

Jahan et al. conducted an experimental investigation with ﬁnish in die-sinking EDM the view of obtaining process of tungsten carbide using different tool electrodes such as tungsten, copper tungsten and silver tungsten [40]. It ﬁnish has been inﬂuenced by has been found that the surface the discharge energy during machining process. It has been realized that the lower discharge energy has produced good ﬁnish. Yeo et al. discussed about the machining of surface zirconium based bulk metallic glass by EDM process with different tool electrodes such as copper, brass and tungsten rod electrode [41]. The experimental results have shown input energy has produced the that the usage of lower surface roughness and electrode tool wear. Khanra et al. input on the workpiece surface during the machining in the EDM process. In this experimental investigation, a well-polished mild steel 0.18%) plate has been used for machining by EDM [42]. It has (C been observed that the energy input has inﬂuenced the debris particle size in the EDM process. Popa et al. showed the

importance of optimizing the process parameters that could inﬂuence the quality of the EDM process [43]. They formulated the equation of crater depth in terms of discharge energy in EDM process. From the relation, it has been observed that the crater depth has been increased ﬂowing through the workpiece and with the discharge current tool electrode. Kojima et al. described about the spectroscopic

Yilmaz et al. introduced a used friendly intelligent system based on the knowledge of the skilled operators for the selection of the EDM process parameters for machining AISI 4340 stainless steel [51]. The system has been provided with a compact selection tool based on expert rules and enabled an unskilled user to select necessary parameters which lead to lower electrode wear rate and better surface quality. Zhou and

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Han developed an adaptive control system which directly and automatically has regulated the tool down time for improving the process performance in EDM process [52]. It has been observed that this adaptive system would improve the machining rate, due to the automatic adjustment of spark gap. Yan and Chien developed a new pulse discriminating and control system for process monitoring in EDM process [53]. The effects of pulse interval, machining feed rate and workpiece on the variation of the proportion of normal spark, arc and short circuit in the total spark have been discussed. The experimen- tal results have indicated that the developed control system has signiﬁcantly reduced the arc discharge in EDM process to achieve stable machining.

observed that machining time plays a major role to improve the process efﬁciency. Das and Joshi developed a comprehen- sive mathematical model to predict the spark erosion rate involved in EDM process [60]. They found that the plasma current and plasma radius have been increased with pulse duration. Salonitis et al. developed the thermal based model for the determination of the material removal rate and average surface roughness achieved as a function of the process parameters in the EDM process [61]. Spadlo et al. developed a thermo model for brush electrical discharge alloying process [62]. It has been realized that material removal depends on the ﬂowing through the dielectric medi- discharge current pulse um.

8.2.

Optimization of EDM process

in EDM process

results have

indicated

that

Chang designed a proportional derivative controller of the spark gap between an electrode and a workpiece to analyze the non-linearity involved in EDM process [54]. They concluded that this non-linearity has reduced the effective discharge in electrical discharge machining process. Behrens and Ginzel proposed a neuro-fuzzy based gap width controller for a highly efﬁcient removal mechanism [55]. The experimental the proposed controller has enhanced EDM process to achieve the better ﬁnish of workpiece. Kao and Shih monitored the surface discharge current in electrical discharge machining using high speed data acquisition with high frequency response [56]. From the experimental results, it has been found that decrease in air gap between tool and workpiece has improved the material removal rate in EDM process.

Tong et al. designed an experimental system with a macro/ micro dual feed spindle to improve the machining perfor- mance of servo scanning micro EDM process, which utilized an ultrasonic linear motor as the macro drive and a piezoelectric actuator as micro feeding mechanism [57]. Based on LabVIEW software package, a real time control system has been developed to control coordinately the dual-feed spindle to drive the tool electrode. Fenggou and Dayong presented a method to automatically determine and optimize the process parameters on the EDM sinking process with the application of artiﬁcial neural network [58]. The experimental results have proved that automatic determination of current value would be the efﬁcient method on improving EDM performance.

Most of the research works have been carried out to optimize the electrical process parameters in EDM process. Marafona and Wykes described an investigation into the optimization of material removal rate in the electric discharge machining process with copper tungsten tool electrode [63]. From the experimental results, it has been proved that large current intensity would result in higher material removal rate. Matoorian et al. presented the application of the Taguchi robust design methods to optimize the precision and accuracy of the EDM process for machining of precise cylindrical forms on hard and difﬁcult-to-machine materials [64]. They found that the current intensity of the EDM process affects the material removal rate greatly. Muthuramalingam and Mohan developed Taguchi-DEAR methodology based optimization of electrical process parameters [65]. Tzeng and Chen described about the application of the fuzzy logic analysis coupled with Taguchi methods to optimize the precision and accuracy of the high speed electrical discharge machining process [66]. The most important factors affecting the precision and accuracy of the high speed EDM process have been identiﬁed as duty cycle and peak current. Kuriakose and Shunmugam developed a multiple regression model to represent relationship between the input and output process variables [67]. They have done the multi objective optimization method based on non- dominated sorting genetic algorithm to optimize the EDM process parameters.

8. Modeling of EDM process parameters

9. Conclusion

in any of the machining process. This section

The process parameters modeling helps to analyze the inﬂuence process parameters on the machining character- is istics discussed about the mathematical modeling of process parameters and simulation models in the EDM process.

8.1.

Theoretical modeling of EDM process

The present study discussed about the review of contribution of electrical process parameters for efﬁcient EDM process in various aspects such as state of art, inﬂuence of the discharge energy, modeling of EDM process parameters, pulse genera- tors, pulse shape, monitoring the parameters and optimiza- tion of EDM process parameters. The review has been carried out in all aspects and types of EDM process such as die-sinking EDM, wire EDM and micro EDM. The following conclusions can be mainly made based on the literatures:

Since the two electrical conductors such as tool electrode and workpiece are separated by a dielectric medium, the EDM arrangement can be modeled as a capacitor. Liu et al. constructed a plate capacitor model for electrical discharge machining process [59]. The correlation actions of process parameters and energy distribution have been discussed ﬁeld electron emission theory. It has been based on the

(i) Most of the literatures have discussed about inﬂuence of process parameters on the performance measures, modeling and optimization of process parameters in- volved in the electro erosion process.

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(ii) It has been found that peak current and pulse duration are

machining, Materials and Manufacturing Processes 28 (2013) 375–380.

dominating the performance measures in EDM process.

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on the EDM performance of Si3N4 CIRP Annals

[19] V.

(iii) It has been observed that only less attention has been given for enhancing the electrical process parameters in EDM process in terms of pulse modiﬁcation, monitoring and adaptive controlling of the process parameters. (iv) It has also been observed that only very few literatures are available describing the hybrid modern manufacturing techniques such as electro chemical discharge machining (ECDM).

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