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Research Papers

Atomized Dielectric Spray-Based Electric Discharge Machining for Sustainable Manufacturing

[+] Author and Article Information
Arvind Pattabhiraman, Deepak Marla

Department of Mechanical Science
and Engineering,
University of Illinois at Urbana-Champaign,
Urbana, IL 61801

Shiv G. Kapoor

Professor
Department of Mechanical Science
and Engineering,
University of Illinois at Urbana-Champaign,
Urbana, IL 61801
e-mail: sgkapoor@illinois.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received June 16, 2015; final manuscript received September 23, 2015; published online October 12, 2015. Assoc. Editor: Stefan Dimov.

J. Micro Nano-Manuf 3(4), 041008 (Oct 12, 2015) (8 pages) Paper No: JMNM-15-1037; doi: 10.1115/1.4031666 History: Received June 16, 2015; Revised September 23, 2015

A novel method of using atomized dielectric spray in micro-electric discharge machining (EDM) (spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the interelectrode gap and acts as a single phase dielectric medium between the electrodes and also effectively removes the debris particles from the discharge zone. Single-discharge micro-EDM experiments are performed using three different dielectric supply methods, viz., conventional wet-EDM (electrodes submerged in dielectric medium), dry-EDM, and spray-EDM in order to compare the processes based on material removal, tool electrode wear, and flushing of debris from the interelectrode gap across a range of discharge energies. It is observed that spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study. The tool electrode wear using atomized dielectric is significantly better than dry-EDM and comparable to that observed in wet-EDM. The percentage of debris particles deposited within a distance of 100 μm from the center of EDM crater is also significantly reduced using the spray-EDM technique.

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Figures

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Fig. 1

Schematic of spray-EDM setup: 1—mounting frame, 2—ultrasonic atomizer housing, 3—dielectric fluid inlet, 4—high-pressure gas inlet, 5—nozzle assembly, 6—dielectric film, 7—gap controlling system, 8—tool electrode, 9—workpiece, and 10—workpiece mounting stage

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Fig. 2

Schematic of spray parameters: 1—nozzle assembly, 2—atomized spray, 3—tool electrode, 4—dielectric film, 5—workpiece, 6—point of spray impingement, Ls—spray length, ds—distance from spray, and α—angle of spray impingement in XZ plane

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Fig. 3

Regimes of droplet–surface interaction: stick, rebound, spread, and splash regimes

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Fig. 4

Spray system with ultrasonic atomizer and nozzle unit: 1—nozzle assembly, 2—atomizer tip, 3—dielectric fluid inlet, 4—high-pressure gas inlet, 5—plastic housing, 6—carrier gas nozzle, and 7—droplet nozzle

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Fig. 5

Sample image of film at distance of 1–2 mm from the point of impingement for P = 0.8 MPa and α = 30 deg

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Fig. 6

Film thickness measurements for different P and α

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Fig. 7

Velocity profiles in interelectrode gap

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Fig. 8

Schematic of methodology of force calculation

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Fig. 9

Force exerted on tool electrode for different P and α

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Fig. 10

Voltage and current during a single-discharge process for Vo = 100 V, ton = 5 μs, and dgap = 1 μm

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Fig. 11

The 3D topography of crater using laser scanning [28]

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Fig. 12

Comparison of wet-EDM, spray-EDM, and dry-EDM: (a) discharge energy and (b) crater volume

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Fig. 13

SEM images of tool electrodes before and after five discharges: (a) and (b): wet-EDM; (c) and (d): spray-EDM; and (e) and (f): dry-EDM

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Fig. 14

Distribution of debris particles from the crater center: (a) wet-EDM; (b) spray-EDM; and (c) dry-EDM

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