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archives of civil and mechanical engineering xxx (2014) xxxxxx
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Review
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abstract
Article history:
Since the thermal energy produced in electrical discharge machining process is due to the
applied electrical energy, it is very important to enhance the electrical process parameters to
improve the process efciency. The present study discusses about having an overview of the
EDM process, modeling of process parameters, and inuence of process parameters such as
input electrical variables, pulse shape, and discharge energy on performance measures such
Keywords:
as material removal rate, surface roughness and electrode wear rate. This study also
EDM
discusses about controlling the electrical process parameters, and empirical relationships
EWR
between process parameters and optimization of process parameters in EDM process. From
Discharge
the review results, it has been observed that the efcacy of the machining process can be
MRR
improved by electrical process parameters, and only less attention has been given for
Surface
1.
Introduction
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
3.
Enhancing the performance of pulse
generator
2.
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
4.
Inuence of pulse shape on performance
measures
Studying the variation of the EDM process response characteristics 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
inuence of the current impulse on machining tungsten
5.
Inuence of electrical process parameters
on performance measures
Fig. 3 Relation between pulse shape and machining
characteristics in EDM process.
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
6.
Inuence of discharge energy on
performance measures
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 inuence of the
pulse energy on the machining characteristics in such a
process.
Jahan et al. conducted an experimental investigation with
the view of obtaining ne surface nish in die-sinking EDM
process of tungsten carbide using different tool electrodes
such as tungsten, copper tungsten and silver tungsten [40]. It
has been found that the surface nish has been inuenced by
the discharge energy during machining process. It has been
realized that the lower discharge energy has produced good
surface nish. Yeo et al. discussed about the machining of
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
that the usage of lower input energy has produced the
lower surface roughness and electrode tool wear. Khanra
et al. investigated the inuence of energy input on the
workpiece surface during the machining in the EDM process.
In this experimental investigation, a well-polished mild steel
(C 0.18%) plate has been used for machining by EDM [42]. It has
been observed that the energy input has inuenced the debris
particle size in the EDM process.
Popa et al. showed the importance of optimizing the
process parameters that could inuence 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
with the discharge current owing through the workpiece and
tool electrode. Kojima et al. described about the spectroscopic
7.
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
8.
8.1.
8.2.
9.
Conclusion
Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
(ii) It has been found that peak current and pulse duration are
dominating the performance measures in EDM process.
(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 modication, 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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Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009
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Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,
Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009