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In the current research work, in-house developed and fabricated multi-axis near-dry Electrical Discharge Machine (near-dry EDM) has been used having different tool positions, i.e. tool electrodes in horizontal position (Case-I) and vertical positions (Case-II) as a novel machining techniques in hard-to-reach places and also to improve the process performance. Design of Experiment tool has been used with three process parameters: voltage, discharge current, and pulse-on-time for experimentation purposes. In order to maximize Material Removal Rate (MRR), it was necessary to compare and enhance these parameters in both cases, i.e. Case-I, and Case-II. The machining process is significantly influenced by the vertical tool positions, as indicated by the largest percentage contribution in the Analysis of Variance results. The voltage has the least influence, while the pulse-on time is relatively less. In contrast, for the horizontal tool position, the voltage proved the most prominent factor in terms of influence, while the current ranked second in significance. Conversely, the pulse-on time exhibited the least impact among the three factors. The highest MRR 2.45 mm3/min was achieved in the vertical tool position while in horizontal machining, the highest MRR 0.144 mm3/min was observed. These findings provide valuable insights into the multi-axis near-dry EDM with proposed methodology. [ABSTRACT FROM AUTHOR]

Micro Electro-Discharge Machining is a precision machining process that uses electrical discharge to produce small-scale components with high accuracy. A metal workpiece is machined in this process by repeatedly generating spark between a tool electrode and the workpiece, removing material in a controlled manner. The significance of µ-EDM lies in its ability to produce highly accurate and complex components with a high surface finish, making it ideal for use in various industries, including aerospace, medical, and electronics. The critical parameters to the success of µ-EDM include the electrical discharge energy, voltage, current, pulse duration, and spark gap between the tool electrode and workpiece, including the shape and size of the tool electrode. This review article discusses the µ-EDM process used to machine biological materials and also examines the µ-EDM, dry µ-EDM procedure, and the features of biomedical materials for biocompatibility, 3D micro shape machining with tool wear composition, and thin film coating for microelectrodes. The impact of introducing nanoparticles to dielectric fluids is further clarified in this article. This study addresses the prospective future research subjects and application areas for the µ-EDM process in order to fulfill the demanding criteria for biomaterials and their usage in the production of bioimplants. [ABSTRACT FROM AUTHOR]

The area of metallurgy has witnessed many advancements in the development of novel electrically conductive materials that shows exceptional mechanical as well as thermal properties. Nonetheless, traditional machining techniques encounter difficulties while machining hard materials. In order to address this limitation, electrical discharge machining (EDM) has emerged as a widely utilised method for machining of intricate geometries and the hard materials. EDM is a category of thermo-electric process that employs rapid recurring sparks between the electrode and work material, eroding the material without direct contact. As there is no contact between the electrode and work material, the issues related to machining defects such as mechanical stresses, clattering, and vibration eliminates. However, EDM have some limitations like poor surface finish and low volumetric material removal. To overcome these kind of limitations, the introduction of metallic powder into the dielectric fluid has been explored in powder-mixed electric discharge machining (PMEDM). This introduction of powder during the process leads to enhance the conductive strength of the fluid and increases the spark gap distance between the electrode and counter material. The inclusion of powder has a significant impact on the performance of the EDM process. Hence, this review aims to facilitate researchers in comprehending the concept of PMEDM and to examine the process parameters required to achieve improved levels of quality. [ABSTRACT FROM AUTHOR]

This work aims to optimize the machining parameters and study the effect of powder-mixed dielectric fluid on the electrical discharge machining (EDM) process. The TOPSIS method of optimization is adopted to identify the optimal machining parameters. HCHCr die steel is preferred as a machining material. Due to their hard and ductile nature, Ni, Zr, and Ni+Zr were selected as powder inclusion in dielectric fluid. An L9 array Taguchi DOE is preferred to perform the experiments with parameters like peak off time, pulse off time, and pulse current. TOPSIS study revealed that the third level of powder dielectric fluid (Ni+Zr), 7A peak current, 9 µs pulse on time, and 2 µs pulse off time were specified as the optimal condition. Pulse on time (Ton) significantly impacted metal removal rate and surface roughness while machining operation on HCHCr die steel. SEM analysis was done to find the effect of powder-mixed dielectric fluid, while EDAX analysis was done to ensure the presence of powder inclusion. [ABSTRACT FROM AUTHOR]

WEDM (Wire electrical discharge machining) is a precision machining method for cutting electrically conductive materials. It is an unconventional machining process that produces precision parts that match the dimensional tolerances of our designs within the range of ±0.0001mm. As the residual stress results in premature failure of parts, the WEDM is preferred for hard to machine materials such as Inconel, Nickel, and other Super alloys. In the present paper, earlier and recent work was reviewed, segregated and evaluated on the effect of wire material, diameter, dielectric fluid, wire wear, pulse on and off times and machining characteristics such as kerf size, machining efficiency, material surface characteristics, etc. This paper also focused on hybrid and ultrasonic-assisted WEDM used for machining of different materials. This paper discussed the major research studies in WEDM. [ABSTRACT FROM AUTHOR]

Machining of difficult-to-machine materials produces huge amount of slurry and harmful aerosol concentration in the atmosphere, which are investigated in this work. In this study, an integrated framework was designed for the multi-response parametric optimization of powder-mixed electrical discharge machining of tungsten carbide alloy keeping into account both manufacturing and environmental aspects. Experiments were conducted using Taguchi L27 orthogonal array (OA), and process optimization was achieved using grey, grey-fuzzy, and grey-adaptive neuro fuzzy inference system–integrated approach. The multi-objective optimization techniques provide optimal parameter settings, i.e. medium pulse-on time (50 µs), low dielectric level (40 mm), medium current intensity (6 A), and high flushing pressure (0.6 kg/cm2). Results conclude that medium input discharge energies (pulse-on time and current intensity) are optimal for machining difficult-to-machine materials to produce low aerosol concentration. The comparison between the grades was performed to show the effectiveness of optimization approaches relative to each other. Finally, confirmation experiments were also conducted to indicate the effectiveness of the adopted optimization approach. [ABSTRACT FROM AUTHOR]

High-speed wire electrical discharge machining (WEDM-HS) of materials of super-high thickness (more than 1000 mm) is a challenging problem. First, sufficient energy is required to maintain the inter-electrode normal discharge. Next, there must be adequate inter-electrode dielectric fluid. Third, in order to generate a smooth cut surface, it is necessary to suppress the vibration of the wire electrode to reduce vibration lines on the cutting surface. To better understand these challenges, the energy and the flow of the medium between two electrodes were analyzed, allowing the establishment of a relevant model. The results indicated that for super-highthickness machining, the pulse energy must be adequate to compensate for the energy consumed in the molybdenum wire and inter-electrode working liquid. In addition, the running speed of the wire electrode should be improved to ensure that there is a sufficiently high flow rate of the dielectric fluid. The servo control mode of the existing machine tools and dielectric fluid were improved and then a process experiment was performed. The experimental results show that the process can be carried out efficiently and stably and the workpiece surface can be cut smoothly using the improved working liquid and servo control mode. [ABSTRACT FROM AUTHOR]

This study addresses micro-slit EDM machining feasibility using pure water as the dielectric fluid. Experimental results revealed that pure water could be used as a dielectric fluid and adopting negative polarity EDM machining could obtain high material removal rate (MRR), low electrode wear, small slit expansion, and little machined burr, compared to positive polarity machining. In comparing kerosene versus pure water, pure water was observed to cause low carbon adherence to the electrode surface. Also discharge energy does not decrease and the discharge processes are not interrupted. Therefore, MRR was higher, and related electrode wear ratio compared to kerosene use was lower. In a continual EDM with multi-slit machining, kerosene will cause carbon element adherence, creating an initially high MRR and electrode wear, with rapid decline. However, pure water will not cause carbon element adherence on the electrode surface, so MRR and electrode wear is always stable in this process. [ABSTRACT FROM AUTHOR]

We report an outbreak of irritant contact dermatitis in the aerospace industry from electrodischarge machining (EDM). 20 workers doing EDM developed irritant contact dermatitis from the dielectric fluid used in EDM. a form of precision metal machining that is widely used in mould making and precision engineering. Dielectric fluid contains hydrocarbons that are aromatic, paraffinic or naphthenic and are skin irritants. irritant contact dermatitis from dielectric fluid has not been reported previously. EDM will become more widespread and occupational dermatitis from dielectric fluid is likely to become more prevalent in the future. Our experience was that irritant contact dermatitis from dielectric fluid can be prevented by simple preventive measures such as personal hygiene and health education. [ABSTRACT FROM AUTHOR]