Kibria / Jahan / Bhattacharyya Micro-electrical Discharge Machining Processes

Technologies and Applications
1. Auflage 2018
ISBN: 978-981-13-3074-2
Verlag: Springer Nature Singapore
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 320 Seiten

Reihe: Materials Forming, Machining and Tribology

This book offers a comprehensive collection of micro electrical discharge machining (EDM) processes, including hybrid processes. It discusses the theory behind each process and their applications in various technological as well as biomedical domains, and also presents a brief background to various micro EDM processes, current research challenges, and detailed case studies of micro-manufacturing miniaturized parts. The book serves as a valuable guide for students and researchers interested in micro EDM and other related processes.  


Dr. Golam Kibria is an Assistant Professor at the Department of Mechanical Engineering, Aliah University, Kolkata. He graduated in Mechanical Engineering from Kalyani Government Engineering College, West Bengal. He completed his M.Tech. in Production Engineering at Jadavpur University, Kolkata in 2008, followed by his Ph.D. at the same university in 2014. After working at Sikkim Manipal University for a year he joined Aliah University, Kolkata. His research interests include non-conventional machining processes, micromachining and advanced manufacturing and forming technology. He is a life member of The Institution of Engineers (IEI), India. He has published more than 20 research articles in peer-reviewed international and national journals, and about 40 papers in conference proceedings. He has authored 5 book chapters and is also an editorial board member and reviewer for a number of respected journals. Dr. Muhammad Pervej Jahan an Assistant Professor at the Department of Mechanical and Manufacturing Engineering at Miami University. His research and teaching interests include advanced manufacturing, non-conventional manufacturing processes, and micro- and nano-machining. He received his B.S. and Ph.D. in Mechanical Engineering from Bangladesh University of Engineering and Technology (BUET) and National University of Singapore (NUS), respectively. He has published over 50 research articles in peer-reviewed journals and international conferences, and also contributed several book chapters. Dr. B. Bhattacharyya is a Professor and former Head of the Production Engineering Department, Jadavpur University. He is also the coordinator of the Center of Advanced Study Program at the University Grants Commission (UGC) and the AICTE Quality Improvement Programme at Jadavpur University. His major research areas include non-traditional machining, micromachining, and advanced manufacturing systems. He has published more than 100 research articles in national and international journals, and around 270 papers in conference proceedings. He has guided several doctoral students and also successfully completed a number of research projects. In addition to authoring several book chapters, Dr. Bhattacharyya has recently published a book titled Electrochemical Micromachining for Nanofabrication, MEMS and Nanotechnology. He is also a recipient of the Career Award of UGC, New Delhi.  

Autoren/Hrsg.

Kibria, Golam

Jahan, Muhammad P.

Bhattacharyya, B.

Inhaltsverzeichnis

1;Preface;6
2;Acknowledgements;9
3;Contents;10
4;About the Editors;12
5;1 Micro-EDM Drilling;14
5.1;1.1 Introduction;14
5.2;1.2 Necessity for Micro-EDM Drilling;15
5.3;1.3 Working Principle;16
5.4;1.4 Process Parameters and Performance Criteria;18
5.5;1.5 Micro-EDM Drilling of Hard-to-Cut Materials;21
5.5.1;1.5.1 Stainless Steel;22
5.5.2;1.5.2 Ni Alloys;25
5.5.3;1.5.3 Ti Alloys;29
5.6;1.6 Challenges and Future Trends of Micro-EDM Drilling;31
5.7;1.7 Summary;32
5.8;References;32
6;2 Micro-electrical Discharge Milling Operation;35
6.1;2.1 Introduction;36
6.2;2.2 Approaches to Generate Depth in Micro-ED-Milling Operation;39
6.2.1;2.2.1 Layer-by-Layer Machining Approach;39
6.2.2;2.2.2 Bulk Machining Approach;41
6.3;2.3 Micro- Versus Macro-ED-Milling Operation: Possible Modifications;43
6.3.1;2.3.1 Discharge Energy Per Pulse;43
6.3.2;2.3.2 Tool Electrode;44
6.3.3;2.3.3 Inter-Electrode Gap;44
6.3.4;2.3.4 Resolution of the Machine Tool Axes;44
6.3.5;2.3.5 Short-Circuit Detection;45
6.4;2.4 Process Variables and Responses Pertaining to the µED-Milling Operation;45
6.5;2.5 Various Micro-fabrication Techniques;46
6.6;2.6 Tool Fabrication Techniques for Micro-ED-Milling Operation;48
6.7;2.7 Physical Behavior of the Micro-ED-Milling Operation;49
6.8;2.8 Micro-ED-Milling Operation with Different Variants;50
6.8.1;2.8.1 Insulating Ceramics;50
6.8.2;2.8.2 Modifications in the Dielectric Fluid;51
6.9;2.9 Allied EDM Processes for 3D Fabrication;52
6.10;2.10 Tool Wear Analysis in ED-Milling Operation;53
6.10.1;2.10.1 Tool Wear Compensation Techniques in Layer-by-Layer Machining;53
6.10.2;2.10.2 Tool Wear in Bulk Machining Approach;56
6.11;2.11 Potential Applications;59
6.12;2.12 Advantages;60
6.13;2.13 Disadvantages;60
6.14;2.14 Summary;60
6.15;References;61
7;3 Micro-EDM with Translational Tool Motion: The Concept of Micro-Electro-Discharge-Slotting;64
7.1;3.1 Feature Generation Using Micro-EDM with Tool Actuation: A Comparative Assessment;64
7.2;3.2 Concept of Micro-Electro-Discharge-Slotting;66
7.3;3.3 Micro-electrode Fabrication: Concept of FAST;67
7.4;3.4 Case Study: Generation of Linear Micro-slots with Conventional EDM Tool;70
7.4.1;3.4.1 Effect of Process Parameters on Overcut and Slot Quality;71
7.4.2;3.4.2 Effect of Process Parameters on Tool Wear Conditions;73
7.5;3.5 Application of Micro-ED Slotting in Micro-feature Generation;75
7.6;3.6 Summary;76
7.7;References;76
8;4 Micro-Wire-EDM;77
8.1;4.1 Introduction;77
8.2;4.2 Process Mechanism of Macro- and Micro-WEDM;79
8.3;4.3 Micro-wire-EDM System Components;81
8.3.1;4.3.1 Wire Running System;81
8.3.2;4.3.2 Computerized Numerical Control System (CNC System);82
8.3.3;4.3.3 Power System;83
8.3.4;4.3.4 Dielectric Flushing System;84
8.3.5;4.3.5 Filtering Systems and Deionizing Subsystem;85
8.4;4.4 Micro-WEDM Parameters and Wire Materials;85
8.4.1;4.4.1 Electrical Parameters;85
8.4.2;4.4.2 Non-electrical Parameters;86
8.4.3;4.4.3 Wire Materials;87
8.5;4.5 Variants of Micro-wire-EDM;88
8.5.1;4.5.1 Cylindrical Micro-WEDM;88
8.5.2;4.5.2 Micro-WEDG;89
8.5.3;4.5.3 Rotary Disc Micro-EDG and Micro-EDM;90
8.6;4.6 Applications of Micro-wire-EDM;91
8.6.1;4.6.1 In Situ Microelectrode Fabrication for Micro-EDM;91
8.6.2;4.6.2 Microelectrode Fabrication for MEMS Application;92
8.6.3;4.6.3 Micro-gear Fabrication;92
8.6.4;4.6.4 Fabrication of PCD Planarization Tool for Polishing Silicon for Semiconductor Industries;93
8.6.5;4.6.5 Microstructuring of Complex 3D Parts;95
8.7;4.7 Advanced Research on Micro-wire-EDM;96
8.7.1;4.7.1 Applications of Micro-WEDM in Hybrid Micromachining;96
8.7.2;4.7.2 Modelling of the Spark Erosion and Process Mechanism;97
8.7.3;4.7.3 Enhancing the Performance of Micro-WEDM by Assistance of Vibration;97
8.7.4;4.7.4 Enhancing the Performance of Micro-WEDM of Silicon Using Conductive Coating;98
8.7.5;4.7.5 Development of Dry Micro-WEDM;99
8.8;4.8 Challenges in Micro-WEDM and Future Research Opportunities;99
8.9;References;100
9;5 Reverse Micro-EDM;103
9.1;5.1 Introduction;103
9.2;5.2 High Aspect Ratio Arrayed Features: Manufacturing Processes and Applications;104
9.3;5.3 Textured Surfaces: Manufacturing Processes and Applications;106
9.4;5.4 Basics of Reverse Micro-Electrical Discharge Machining (R-MEDM);106
9.5;5.5 Machining of High Aspect Ratio Features Via R-MEDM;112
9.5.1;5.5.1 Reverse Micro-EDM of Easy-to-Erode (Brass) Material;113
9.5.2;5.5.2 Reverse Micro-EDM of Difficult-to-Erode (Tungsten Carbide) Material;114
9.6;5.6 Process Mechanics Comparison of R-MEDM and Micro-EDM;116
9.7;5.7 Vibration-Assisted Reverse Micro-EDM for Texturing Applications;121
9.8;5.8 Debris Modeling in Vibration-Assisted Reverse Micro-EDM;127
9.9;5.9 Summary;132
9.10;References;132
10;6 Micro-EDM Performance Using Different Dielectrics;135
10.1;6.1 Introduction;135
10.2;6.2 Role of Dielectric;136
10.3;6.3 Water-Based Dielectric;136
10.4;6.4 Micro-EDM with Water-Based Organic Compounds;137
10.5;6.5 Powder-Mixed Micro-EDM;138
10.6;6.6 Gas-Assisted Micro-EDM;141
10.7;6.7 Micro-EDM with Less Viscous Dielectric Oils;144
10.8;6.8 Summary;144
10.9;References;144
11;7 Powder-Mixed Microelectric Discharge Machining;146
11.1;7.1 Introduction;146
11.2;7.2 Working Principle;147
11.3;7.3 Pulse Generator;149
11.4;7.4 PMµEDM Process Parameters;152
11.4.1;7.4.1 Electrical Parameters;152
11.4.2;7.4.2 Non-electrical Parameters;156
11.5;7.5 Effect of Powder on IEG;157
11.6;7.6 Effect of Powder on MRR;157
11.7;7.7 Effect of Powder on Tool Wear Rate;159
11.8;7.8 Effect of Powder on Machining Time;160
11.9;7.9 Effect of Powder on Surface Roughness;161
11.10;7.10 Effect of Powder on Machined Surface;162
11.11;7.11 Research on PMµEDM;164
11.12;7.12 Summary;166
11.13;References;167
12;8 Vibration-Assisted Micro-EDM Process;169
12.1;8.1 Introduction;169
12.2;8.2 Challenges in Micro-EDM;170
12.3;8.3 Improvement of Machining Performances of ?-EDM with Aid of Vibration;171
12.3.1;8.3.1 Effects of High-Frequency Vibration;171
12.3.2;8.3.2 Effects of Low-Frequency Vibration;178
12.3.3;8.3.3 Effects of Inclined Feeding with Low-Frequency Vibration;187
12.3.4;8.3.4 Self-adaptive Control in Micro-EDM;189
12.4;8.4 Summary;191
12.5;References;192
13;9 Tool Wear Compensation in Micro-EDM;193
13.1;9.1 Introduction;194
13.1.1;9.1.1 ?-EDM Drilling;194
13.1.2;9.1.2 ?-EDM Milling;196
13.1.3;9.1.3 Reverse ?-EDM Method;197
13.2;9.2 Tool Wear Compensation Methodologies;199
13.2.1;9.2.1 Offline Tool Wear Compensation;200
13.2.2;9.2.2 Online Tool Wear Compensation;200
13.3;9.3 Authentication of Proposed Method;210
13.3.1;9.3.1 Proposed Process;210
13.3.2;9.3.2 Uniform Wear Method;211
13.4;9.4 Results and Discussion;212
13.5;9.5 Summary;214
13.6;References;215
14;10 Sequential Micro-EDM;217
14.1;10.1 Introduction;218
14.2;10.2 Advantages and Properties of Sequential Micro-EDM;219
14.3;10.3 Prerequisites of Sequential Micromachining;220
14.4;10.4 Sequential Micro-EDM and Its Applications;220
14.4.1;10.4.1 Sequential Micro-EDM and Micro-grinding;220
14.4.2;10.4.2 Sequential Micro-EDM and Micro-milling;222
14.4.3;10.4.3 Sequential Micro-EDM and Micro-ECM;224
14.4.4;10.4.4 Sequential Micro-EDM and Laser Micromachining;227
14.4.5;10.4.5 Sequential Micro-EDM and LIGA;230
14.4.6;10.4.6 Sequential Micro-EDM and Micro-turning;233
14.4.7;10.4.7 Sequential Micro-EDM, Micro-drilling and Electropolishing;234
14.5;10.5 Summary;235
14.6;References;236
15;11 Near Net Shape Machining by Micro-EDM and Micro-WEDM;238
15.1;11.1 Introduction;238
15.2;11.2 ?EDM as a Near Net Shape (NNS) Process;240
15.2.1;11.2.1 ?EDM for Fabricating Micro-holes and Micro-hole Array;240
15.2.2;11.2.2 Batch Mode Fabrication by ?EDM;247
15.2.3;11.2.3 3D Fabrication by Scanning/Milling ?EDM;251
15.3;11.3 ?WEDM as a Near Net Shape (NNS) Process;257
15.3.1;11.3.1 Wire EDM Parameters and Their Effect on Surface Roughness;259
15.3.2;11.3.2 Application of Wire EDM for Different Metal Composites for Near Net Shape Machining;261
15.3.3;11.3.3 Wire EDM for Special Geometry Design in Near Net Shape Machining;265
15.4;11.4 Summary;268
15.5;References;268
16;12 Micro-electrochemical Discharge Machining;272
16.1;12.1 Introduction;273
16.2;12.2 Micro-electrochemical Discharge Machining;273
16.3;12.3 Machining System and Equipments for ?-ECDM;274
16.3.1;12.3.1 Machining Chamber;275
16.3.2;12.3.2 Power Supply System;276
16.3.3;12.3.3 Electrolyte Feeding System;276
16.3.4;12.3.4 Gap Control Unit;277
16.3.5;12.3.5 Vision (Monitoring) System;279
16.3.6;12.3.6 Exhaust System;280
16.4;12.4 Electrochemical Discharge Phenomenon;280
16.4.1;12.4.1 Electrochemical Reactions;281
16.4.2;12.4.2 Coalescence of H2 Bubbles;283
16.4.3;12.4.3 Ionization;284
16.4.4;12.4.4 Electrical Discharge/Spark Formation;284
16.4.5;12.4.5 Cavitation;285
16.5;12.5 Mechanism of Machining;285
16.6;12.6 Configurations of ?-ECDM Process;286
16.6.1;12.6.1 Sinking ?-ECDM;287
16.6.2;12.6.2 Drilling ?-ECDM;287
16.6.3;12.6.3 Milling ?-ECDM;287
16.6.4;12.6.4 TW ?-ECDM;288
16.6.5;12.6.5 Grinding ?-ECDM;289
16.6.6;12.6.6 Turning ?-ECDM;289
16.7;12.7 Process Variables and Responses;290
16.7.1;12.7.1 Electrical Parameters;290
16.7.2;12.7.2 Tool Parameters;291
16.7.3;12.7.3 Electrolyte Parameters;292
16.7.4;12.7.4 Flushing Parameters;292
16.7.5;12.7.5 Process Responses;292
16.8;12.8 Process Capabilities;293
16.8.1;12.8.1 Merits;293
16.8.2;12.8.2 Demerits;293
16.8.3;12.8.3 Applications;294
16.9;12.9 Micro-ECDM at a Glance;295
16.10;12.10 Summary;297
16.11;References;297
17;13 Multi-response Optimization of Micro-EDM Processes: A State-of-the-Art Review;299
17.1;13.1 Introduction;300
17.2;13.2 Overview of µ-EDM Process;301
17.2.1;13.2.1 Principle of µ-EDM;301
17.2.2;13.2.2 A Short Review of Experimental Investigation on µ-EDM Process;302
17.3;13.3 Applications of Multi-Criteria Decision-Making (MCDM) Methods for Multi-Response Optimization of µ-EDM Processes;306
17.4;13.4 Methods for Optimization of Performance Characteristic of µ-EDM Processes;307
17.5;13.5 Summary and Future Scopes;308
17.6;References;312
18;Index;317