MACHINING CHARACTERISTICS OF A HYBRID

PROCESS OF EDM IN GAS COMBINED WITH

ULTRASONIC VIBRATION AND AJM

GUIDED BY:-

GOVERNMENT ENGINEERING COLLEGE

IDUKKI

RAJU C
ASSISTANT PROFESSOR
DEPT OF ME

PADMARAJAN P
S7 ME
ROLL NO: 36

CONTENTS

Introduction

Electrical discharge machining (EDM)

Abrasive Jet Machining (AJM)

Ultrasonic Machining (USM)

Hybrid EDM process

Case study

Results and Discussion

Conclusion

References
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INTRODUCTION

EDM,AJM and USM are widely using manufacturing processes.

AJM and USV mechanisms were incorporated into the process of EDM in gas
to develop a hybrid EDM process.

Improves machining characteristics

ELECTRICAL DISCHARGE MACHINING (EDM)

Electrical Discharge Machining (EDM) is a non conventional machining

process.

EDM machining method are used for hard metals which are electrically
conductive.

The principle of EDM is spark erosion or electro erosion.

Uses a pulsating electric charge carrying high frequency DC current.

Generates a plasma channel.

Contd.

Kerosene used as the dielectric media in EDM process.

Dry EDM is a modification of the oil EDM process in which the liquid
dielectric is replaced.

Molten materials during EDM process was ejected from machining zone by a
high-speed air jet. .

ABRASIVE JET MACHINING (AJM)

Abrasive

jet machining (AJM) is process of material removal by impact

erosion.
A

focused stream of abrasive particles 50 microns size , carried by high

pressure air or gas at velocity of 200 m/s is made to impinge on the work
surface.
Aluminum

oxide, Silicon carbide, and sodium bicarbonate are some of

abrasives used in AJM.

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ULTRASONIC MACHINING (USM)

In Ultrasonic machining (USM), tool vibrates at an ultrasonic frequency (2025 kHz) with an amplitude of around 5-50 m over the workpiece.

Tool is pressed downward with a feed force.

As the tool vibrates over the workpiece, the abrasive particles act as the
indenters and indent both the work material and the tool.

HYBRID EDM PROCESS

Develop a hybrid process integrating various mechanisms to improve the

machining characteristics.

The effects of dielectric media and peek current in the hybrid EDM process
were examined on the machining characteristics such as material removal rate
(MRR), electrode wear rate (EWR), and surface roughness (SR).

To find surface morphologies and thickness of recast layer of SKD 61 tool steel
in hybrid process.

CASE STUDY

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A die-sinking EDM machine with transistor controlled

circuit integrated is used.

SKD 61 steel was selected as the workpiece material,

which dimension is 15 mm5 mm.

The dielectric media were adjusted by a regulated pressure

valve to fit the requirement of experimental conditions.

Gas with specific abrasives was delivered through central

hole of electrode.

Melting and vaporizing material was ejected as fast as

possible by high-speed compressed gas jet.

USV and AJM were incorporated to facilitate the materials

removal efficiency.
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Workpiece and electrode specimens were weighed

before and after each experiment to calculate the
MRR and EWR.

The SR was measured by a precision profilometer.

Scanning Electronic microscope (SEM) was used to

explore the integrities of machined surface

The dielectric media were used are air, oxygen, and

argon.

Input variables such as peak current (Ip), dielectric

media were varied to explore their influences on the
machining characteristics.

The machining time for each experiment is 10 min.

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RESULTS AND DISCUSSION

EFFECTS OF THE HYBRID EDM PROCESS WITH VARIOUS
DIELECTRIC MEDIA

MATERIAL REMOVAL RATE

Material removal rate (mg/min)

Higher MRR by hybrid EDM process due to:

Improved transport rate of debris and molten material.
Preventing the secondary sparks .

AIR

OXYGEN
Dielectric Medium

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ARGON

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ELECTRODE WEAR RATE

Electrode wear rate (mg/min)

Higher EWR in hybrid EDM process than EDM in gas.

AJM mechanism abrade the inner wall of the electrode

AIR

OXYGEN
Dielectric

ARGON

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SURFACE ROUGHNESS

Surface roughness (Ra/m)

Lower SR of hybrid EDM process.

Hybrid EDM process reduce the asperities caused by USV
and AJM.
Oxygen:- highest SR -highest MRR generate deeper &
wider craters

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AIR

OXYGEN

ARGON

 EFFECTS OF THE HYBRID EDM PROCESS WITH PEAK

CURRENT

MATERIAL REMOVAL RATE

MRR enhanced with an increase of peak current.

Oxygen: promote oxidation & sparking of EDM.
Material removal rate (mg/min)

Oxygen

Air

Argon

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Peak current, Amp

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ELECTRODE WEAR RATE

Electrode wear rate (mg/min)

EWR increases with the increasing of peak current.

Highest EWR was gained by using oxygen.
Argon has lowest EWR.

Peak current, Amp

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SURFACE ROUGHNESS
SR increased with Ia.
surface morphologies would be coarser & the SR was

Surface roughness (Ra/m)

larger as the peak current set at high levels.

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Peak current, Amp

 SURFACE INTEGRITY

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EDM Incorporated with AJM (EDM+AJM)

Morphology caused by EDM in gas combined AJM
illustrates obvious micro pores on the machined surface.

MICRO PORES

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Hybrid EDM Process (EDM+AJM+USV)

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Molten materials suffer from rapid cooling rate due to the high
compressed dielectric media and the high frequency USV.

MICRO CRACKS

The surface tension stress exceeded the ultra-tensile strength.

Thus, the micro cracks were easily formed.
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 RECAST LAYER

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EDM incorporated with AJM (EDM+AJM)

Thickness

of the recast layer obtained by the EDM in gas

combined AJM is larger than that obtained by the developed hybrid
EDM process.
Epoxy

25.5 m

Recast layer
SKD 61
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Hybrid EDM Process (EDM+AJM+USV)

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Hybrid EDM process incorporates the USV which would inhibit the
molten material to be redeposited on the machined surface.
The recast layer is thinner.

Epoxy

14.6 m

Recast layer

SKD 61
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CONCLUSION

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The MRR and EWR obtained by hybrid EDM process was higher than that by EDM in gas.

SR gained by the hybrid EDM process was lower than that by EDM in gas.

The machining characteristics such as MRR, EWR, and SR increased with an increase of
peak current.

The oxygen dielectric media generated the highest MRR, EWR and SR in hybrid EDM
process.

The argon dielectric media produced the lowest MRR, EWR and SR in hybrid EDM
process.

EDM in gas combined AJM have micro pores on the machined surface, and that from
hybrid EDM process reveals micro cracks on the machined surface.

Thickness of the recast layer obtained by the EDM in gas incorporated with AJM is thicker
than that obtained by the developed hybrid EDM process.
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REFERENCES

Yan-Cherng.Lin,Jung.Chou.Hung,Han-ming.chow,A-Cheng.Wang,Jyun-Ting
Chen,.Machining Characteristics of a Hybrid process of EDM in gas Combined with
ultrasonic vibration and AJM. International journal of Machine tool and
manufacture 2016.

Yan-chernh

LIN,Yuan_Feng

CHEN,A-cheng

WANG,Wan-lin

SEI.Machining

performance of hybrid process of abrasive jet machining and electrical discharge

machining. Transactions of nonferrous metals society of china 2012.

Ravindra nath Yadav,Vinod yadava,.Experimental study of erosion and abrasion

based hybrid machining of hybrid metal matrix composite. International journal of
precision engineering and manufacturing2013.
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THANK YOU

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ANY QUESTIONS ?

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