Effect of material microstructure on the micro-EDM process

Ahmed Elkaseer, Samuel Bigot, Anthony Surleraux, Andrzej Rosochowski

Research output: Contribution to conferencePaper

Abstract

This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the machining response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wear
ratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.
LanguageEnglish
Pages336-343
Number of pages8
Publication statusPublished - Mar 2013
EventICOMM 2013 - Victoria, Canada
Duration: 25 Mar 201328 Mar 2013

Conference

ConferenceICOMM 2013
CountryCanada
CityVictoria
Period25/03/1328/03/13

Fingerprint

Surface roughness
Microstructure
Wear of materials
Equal channel angular pressing
Electric potential
Electric sparks
Refining
Machining

Keywords

  • micro-EDM
  • surface
  • material microstructure

Cite this

Elkaseer, A., Bigot, S., Surleraux, A., & Rosochowski, A. (2013). Effect of material microstructure on the micro-EDM process. 336-343. Paper presented at ICOMM 2013, Victoria, Canada.
Elkaseer, Ahmed ; Bigot, Samuel ; Surleraux, Anthony ; Rosochowski, Andrzej. / Effect of material microstructure on the micro-EDM process. Paper presented at ICOMM 2013, Victoria, Canada.8 p.
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Elkaseer, A, Bigot, S, Surleraux, A & Rosochowski, A 2013, 'Effect of material microstructure on the micro-EDM process' Paper presented at ICOMM 2013, Victoria, Canada, 25/03/13 - 28/03/13, pp. 336-343.

Effect of material microstructure on the micro-EDM process. / Elkaseer, Ahmed; Bigot, Samuel; Surleraux, Anthony; Rosochowski, Andrzej.

2013. 336-343 Paper presented at ICOMM 2013, Victoria, Canada.

Research output: Contribution to conferencePaper

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AU - Elkaseer, Ahmed

AU - Bigot, Samuel

AU - Surleraux, Anthony

AU - Rosochowski, Andrzej

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N2 - This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the machining response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wearratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.

AB - This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the machining response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wearratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.

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Elkaseer A, Bigot S, Surleraux A, Rosochowski A. Effect of material microstructure on the micro-EDM process. 2013. Paper presented at ICOMM 2013, Victoria, Canada.