Abstract
The flushing of by-products from the interelectrode gap (EG) of a few microns is the major concern in the electrical discharge machining (EDM). The inadequate removal of debris from the gap causes short-circuits and reduces machining efficiency. Researchers have explored different techniques to enhance debris flushing from the gap. In electrical discharge milling (ED milling), the rotation of the tool along with linear travel is the major driving force for the debris flushing. In this paper, the application of an improvised tool to enhance rotation induced debris flushing is proposed. The flow-fields of dielectric and debris were modeled using computational fluid dynamics (CFD). The simulations results were utilized to optimize the tool geometries. A comparative study of the cylindrical and improvised tool in terms of material removal rate (MRR), tool wear rate (TWR) and surface finish was calculated. Relative to conventional cylindrical tools, the improvised tool enhanced the MRR by 150 %.
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Satish A. Mullya is an Assistant Professor of Mechanical Engineering at Anna-saheb Dange College of Engineering and Technology Ashta, Sangli Maharashtra, India. He graduated in Pro-duction Engineering from KBP College of Engineering and Technology Satara affiliated to Shivaji University Kolhapur. He received his masters degree in Computer Integrated Manufacturing from NIT Warangal, Andhra Pradesh, and he is currently pursuing the Ph.D. at BITS Pilani K K Birla Goa campus, India.
G. Karthikeyan had his graduation in Mechanical Engineering from Moogam-bigai College of Engineering Pudukottai, Tamil Nadu. He received his masters degree in Manufacturing Technology from Regional Engineering College, Trichy, and his Ph.D. from Indian Institute of Technology, Kanpur. Presently, he is an Assistant Professor in the Department of Mechanical Engineering, BITS Pilani K K Birla Goa Campus, India.
Vaibhav S. Ganachari is an Assistant Professor of Mechanical Engineering at Annasaheb Dange College of Engineering and Technology Ashta, Sangli Maharashtra, India. He had his graduation in Mechanical Engineering from JJ Mag-dum College of Engineering and Technology Sangli, and received his masters degree in Mechanical Engineering from RIT Sakharale; he is currently pursuing the Ph.D. atVTU Belgaum.
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Mullya, S., Karthikeyan, G. & Ganachari, V. An investigation into performance of electric discharge milling using slotted tools. J Mech Sci Technol 34, 2525–2533 (2020). https://doi.org/10.1007/s12206-020-0528-2
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DOI: https://doi.org/10.1007/s12206-020-0528-2