Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Materials - Tập 12 Số 6 - Trang 989
M. Goiogana1, Ahmed Elkaseer2,3
1IK4-Tekniker, Advanced Manufacturing Technologies Unit, Iñaki Goenaga 5, 20600 Eibar, Spain
2Karlsruhe Institute of Technology (KIT), Institute for Automation and Applied Informatics (IAI), Karlsruhe 76344, Germany
3Port Said University, Faculty of Engineering, Department of Production Engineering and Mechanical design, Port Fuad 42526, Egypt

Tóm tắt

This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

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Materials

Tập 12 Số 6

989

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