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Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining
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Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 20058

Special Issue Editor

Dr. Muhammad Pervej Jahan

E-Mail Website
Guest Editor
Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH 45056, USA
Interests: micromachining; micro-electro-discharge machining (micro-EDM); hybrid micromachining; nanomachining; non-conventional machining; additive manufacturing (AM); post-processing of AM parts; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

I would like to invite you to submit your unpublished research on any aspect of electrical discharge machining (EDM) to this Special Issue. Electrical discharge machining (EDM) is one of earliest and most widely used nontraditional machining processes commonly used to machine difficult-to-cut materials. For the capability of machining materials irrespective of their hardness, EDM has found important applications in automotive, electronic, packaging, telecommunication, aerospace, and biomedical industries. Although die-sinker EDM and wire-EDM are two major types of EDM, there has been continuous research on the development of varieties of EDM at multiscales using these two major EDM types. Some of the recent developments are micro-EDM drilling, micro-EDM milling, orbital micro-EDM, and nanoscale EDM. Another recent expansion in the EDM research is the development of EDM-based hybrid machining processes, where another machining process is used either simultaneously or sequentially with EDM to alleviate the shortcomings of the EDM process. Some of the examples of EDM-based hybrid processes are powder-mixed EDM, vibration-assisted EDM, laser-assisted EDM, electrochemical discharge machining (ECDM), etc.

The goal of this Special Issue is to comprehend significant studies and recent advances in the areas of multiscale EDM and EDM-based hybrid machining processes. Experimental investigation, analytical modeling, and numerical simulations in the areas of EDM and EDM-based hybrid processes are of interest. Process development, monitoring, and control of various macro- and microscale EDM-based processes fall within the scope of this Special Issue. Specific topics of interest include but are not limited to:

  • Multiscale EDM processes, i.e., conventional EDM, micro-EDM, nano-EDM;
  • Die-sinker and wire-EDM processes;
  • Variations of EDM, i.e., micro-EDM drilling, micro-EDM milling, orbital EDM, Reverse EDM, dry EDM, etc.;
  • EDM-based hybrid processes, or assisted EDM processes, i.e., vibration-assisted EDM, laser-assisted EDM, powder-mixed EDM, etc.;
  • EDM of difficult-to-cut, newer and novel materials;
  • EDM for innovative applications, such as biomedical implants;
  • EDM process development, monitoring, and control;
  • Optimization of EDM processes.

Dr. Muhammad Pervej Jahan
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Published Papers (7 papers)

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Research

53 pages, 19207 KiB  
Article
Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics
by Eckart Uhlmann, Mitchel Polte, Sami Yabroudi, Nicklas Gerhard, Ekaterina Sakharova, Kai Thißen and Wilhelm Penske
J. Manuf. Mater. Process. 2023, 7(6), 217; https://doi.org/10.3390/jmmp7060217 - 1 Dec 2023
Viewed by 2471
Abstract
The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence [...] Read more.
The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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17 pages, 2787 KiB  
Article
Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V
by Jay Vora, Yug Shah, Sakshum Khanna, Vivek K. Patel, Manoj Jagdale and Rakesh Chaudhari
J. Manuf. Mater. Process. 2023, 7(3), 111; https://doi.org/10.3390/jmmp7030111 - 7 Jun 2023
Cited by 11 | Viewed by 1762
Abstract
Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (Toff), and pulse-on-duration (Toff) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate [...] Read more.
Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (Toff), and pulse-on-duration (Toff) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate (MRR) and surface roughness (SR) were selected as output measures for the study. The experiments were carried out by employing Taguchi’s L9 design at three levels. Empirical models were generated, which give the relationship between the input and output factors of the process. To check the acceptability of the model terms, analysis of variance (ANOVA) was used. The regression mode was observed to be significant for the output measures. For MRR, Toff was recorded as the highly significant factor affecting the response values with 74.95% impact, followed by Ton with 16.39%, and current with 6.56%. In the case of SR, Ton was found to be a highly significant factor with a 50.24% impact, followed by current with 43.99%, and Toff with 1.47%. Further, multi-objective optimization by using the HTS technique was performed. The effect of expanded graphite (EG) nano-powder has been studied on the output factors of MRR and SR. The use of EG nano-powder was found to improve WEDM operations as MRR was increased by 45.35%, and simultaneously, SR was reduced by 36.16%. Lastly, the surface morphology of the machined surface was investigated by employing SEM to understand the effect of EG nano-powder. The results have shown a reduction in surface defects by using EG nano-powder compared to the conventional WEDM process. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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18 pages, 3616 KiB  
Article
Experimental Investigation on the Cutting of Additively Manufactured Ti6Al4V with Wire-EDM and the Analytical Modelling of Cutting Speed and Surface Roughness
by Manuela Galati, Paolo Antonioni, Flaviana Calignano and Eleonora Atzeni
J. Manuf. Mater. Process. 2023, 7(2), 69; https://doi.org/10.3390/jmmp7020069 - 16 Mar 2023
Cited by 9 | Viewed by 2525
Abstract
Additive manufacturing (AM) technologies for metallic materials allow for the manufacturing of high-performance components optimised in weight, geometry, and mechanical properties. However, several post-processing operations are needed after production, including removing parts from the build platform. This operation is essential and must be [...] Read more.
Additive manufacturing (AM) technologies for metallic materials allow for the manufacturing of high-performance components optimised in weight, geometry, and mechanical properties. However, several post-processing operations are needed after production, including removing parts from the build platform. This operation is essential and must be performed rapidly, precisely, and with a good surface finishing. This work presents an experimental investigation of the wire electric discharge machining (W-EDM) process of Ti6Al4V specimens produced by AM technologies. The influence of cutting parameters is analysed compared to the material produced by conventional technology. Models of cutting speed and surface roughness obtained by a W-EDM are inferred from the collected data. Remarkably, the results show that the manufacturing process used to produce the components plays a crucial role in defining the final surface roughness and the most significant parameters affecting the machining performance. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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21 pages, 7168 KiB  
Article
Optimization of Wire-EDM Process Parameters for Al-Mg-0.6Si-0.35Fe/15%RHA/5%Cu Hybrid Metal Matrix Composite Using TOPSIS: Processing and Characterizations
by Jatinder Kumar, Shubham Sharma, Jujhar Singh, Sunpreet Singh and Gurminder Singh
J. Manuf. Mater. Process. 2022, 6(6), 150; https://doi.org/10.3390/jmmp6060150 - 22 Nov 2022
Cited by 23 | Viewed by 2445
Abstract
The current experimental study concerns obtaining the optimal set of wire-EDM processing factors for a novel Al-Mg-0.6Si-0.35Fe/15%RHA/5%Cu hybrid aluminum matrix composite. The composite exhibits hardness of 64.2 HRB, tensile strength 104.6 MPa, impact energy 4.8 joules, when tested using standard testing techniques. For [...] Read more.
The current experimental study concerns obtaining the optimal set of wire-EDM processing factors for a novel Al-Mg-0.6Si-0.35Fe/15%RHA/5%Cu hybrid aluminum matrix composite. The composite exhibits hardness of 64.2 HRB, tensile strength 104.6 MPa, impact energy 4.8 joules, when tested using standard testing techniques. For this, composite is formulated with the help of a stir casting route. The tests are conducted as per Taguchi’s L27 OA, to explore the influence of processing factors on the surface roughness (Ra), radial overcut (ROC) and material removal rate (MRR). The optimization is executed using the Taguchi approach, followed by multiple objective optimizations with TOPSIS (one of the MADM techniques). For optimal values of Ra, MRR and ROC, the optimum set of input variables is suggested as 150 A of current, 125 μs of pulse duration, 50 μs of pulse interval and 8 mm/min of wire feed-rate. Predicted performance index value was calculated and was compared with the experiment value. It has been observed that both values are very close to each other with only 1.33% error, which means the results are validated. ANOVA confirms that current is a predominant factor influencing response characteristic parameters, which contributes 24.09%, followed by pulse duration (16.78%) and pulse interval (15.18%). The surface characterization using a scanning electron microscope (SEM), X-ray diffraction (XRD), energy dispersive spectroscope (EDS) and optical microscope (OM) has also been carried out to affirm the existence of the reinforcing particles in the base matrix. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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11 pages, 2333 KiB  
Communication
High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode
by Eckart Uhlmann, Julian Polte, Jan Streckenbach, Ngoc Chuong Dinh, Sami Yabroudi, Mitchel Polte and Julian Börnstein
J. Manuf. Mater. Process. 2022, 6(5), 113; https://doi.org/10.3390/jmmp6050113 - 1 Oct 2022
Cited by 2 | Viewed by 1929
Abstract
Electro-discharge drilling is a key technology for manufacturing sophisticated nozzles in a broad range of automotive and aerospace applications. The formation of debris in the working gap leads to arcs and short circuits on the lateral surface when state-of-the-art tool electrodes are used. [...] Read more.
Electro-discharge drilling is a key technology for manufacturing sophisticated nozzles in a broad range of automotive and aerospace applications. The formation of debris in the working gap leads to arcs and short circuits on the lateral surface when state-of-the-art tool electrodes are used. As a result, limited drilling depth, increased linear tool wear, and the conicity of boreholes are still challenges. In this work, a new approach for the passivation of the lateral surface of copper tool electrodes by oxidation is shown. The comparison with state-of-the-art tool electrodes showed a reduction in the erosion duration by 48% for machining hardened steel. Promising improvements could be achieved by the thermal oxidation of the tool electrodes with the aim of increasing the electrical resistivity of the lateral surface of the tool electrode. However, due to the loss of strength, the high oxide layer thickness, and the partial delamination of the oxide layer, further comprehensive investigations on the influence of the oxidation temperature need to be conducted. Future adjustments with lower oxidation temperatures will be carried out. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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19 pages, 4357 KiB  
Article
Effect of Thermo-Physical Properties of the Tool Materials on the Electro-Discharge Machining Performance of Ti-6Al-4V and SS316 Work Piece Materials
by Sunita Sethy, Rajesh Kumar Behera, Jõao Paulo Davim and Jaydev Rana
J. Manuf. Mater. Process. 2022, 6(5), 96; https://doi.org/10.3390/jmmp6050096 - 5 Sep 2022
Cited by 10 | Viewed by 2296
Abstract
Electro-discharge machining (EDM) is a useful non-conventional machining operation frequently applied to make different complex geometries in any conducting material. The objectives of the present paper are to study the effect of a variation of thermo-physical properties (TPP) of three different tool materials [...] Read more.
Electro-discharge machining (EDM) is a useful non-conventional machining operation frequently applied to make different complex geometries in any conducting material. The objectives of the present paper are to study the effect of a variation of thermo-physical properties (TPP) of three different tool materials on EDM performances. The different performances compared in this paper are: material removal rate (MRR), tool-wear rate (TWR), surface roughness (SR), radial overcut (ROC), surface-crack density (SCD) and surface hardness. Two of the most widely used work piece materials, such as corrosion-resistant austenitic stainless steel (SS316) and high strength corrosion-resistance titanium alloy (Ti-6Al-4V), are machined with the help of three different tools by varying input current and maintaining constant pulse-on time, pulse-off time and flushing pressure. Microstructural studies of the tool tip surface after machining have also been carried out. It is found that among these three tool materials, the copper tool showed the best machining performance with respect to material removal rate, radial overcut, surface finish and surface-crack density. This work will help industry personnel to choose a suitable tool for a specific work piece material. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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28 pages, 18456 KiB  
Article
Electrical Discharge Machining of Oxide Nanocomposite: Nanomodification of Surface and Subsurface Layers
by Sergey N. Grigoriev, Marina A. Volosova, Anna A. Okunkova, Sergey V. Fedorov, Khaled Hamdy, Pavel A. Podrabinnik, Petr M. Pivkin, Mikhail P. Kozochkin and Artur N. Porvatov
J. Manuf. Mater. Process. 2020, 4(3), 96; https://doi.org/10.3390/jmmp4030096 - 21 Sep 2020
Cited by 38 | Viewed by 3843
Abstract
The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 [...] Read more.
The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 + 30% of TiC was electroerosively machined in a water and hydrocarbon oil. The process of electrical discharge machining is accompanied by oscillations that were registered by diagnostic means. The obtained surface of the samples was researched by the means of scanning electron microscopy and X-ray photoelectron spectroscopy. The observed surface and subsurface changes provide grounding for the conclusions on the nature of processes and reactions that occur between two electrodes and nanomodification of the obtained surfaces that can be an advantage for a series of applications. Full article
(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)
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