Surface modification by electrical discharge machining: A review

Journal of Materials Processing Technology

Volumn 209, Issue 8, 2009, Pages 3675-3687

  Kumar, Sanjeev ^a   Singh, Rupinder ^b   Singh, T P ^c   Sethi, B L ^d  

^a PEC UNIVERSITY OF TECHNOLOGY   (India)

^b GURU NANAK DEV ENGINEERING COLLEGE   (India)

^c THAPAR UNIVERSITY   (India)

^d MAHARISHI MARKANDESHWAR DEEMED TO BE UNIVERSITY   (India)

Author keywords

EDM; Electrical discharge machining; Powder metallurgy electrodes; Surface finish; Surface modification

Indexed keywords

COMPOSITE ELECTRODES; EDM; ELECTRICAL DISCHARGE MACHINING; FUTURE TRENDS; INTRINSIC NATURES; MACHINING CONDITIONS; MATERIAL TRANSFERS; METALLIC POWDERS; NOVEL APPLICATIONS; PLASMA CHANNELS; SURFACE COMPOSITIONS; SURFACE FINISH; SURFACE MODIFICATION; TOOL ELECTRODES; TOOL MATERIALS; WORK MATERIALS;

ALUMINUM POWDER METALLURGY; ELECTRIC DIPOLE MOMENTS; ELECTRIC DISCHARGE MACHINING; ELECTRIC DISCHARGES; ELECTRODES; MACHINERY; METAL RECOVERY; METALLURGY; MICROMACHINING; POWDERS; SURFACE TREATMENT;

SURFACE PROPERTIES;

EID: 64249113833     PISSN: 09240136     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.jmatprotec.2008.09.032     Document Type: Review

References (84)

1. Abu Zeid O.A. On the effect of electrodischarge machining parameters on the fatigue life of AISI D6 tool steel. Journal of Materials Processing Technology 68 1 (1997) 27-32
2. Ahmad M., Senthil Kumar A., and Lim H.S. A study on machining parameters of guided micro-EDM tool with focus on minimizing spark gap. Proceedings of the 22nd AIMTDR Conference. IIT, Roorkee (2006) 869-873
3. Altan T., Lilly B.W., Konig W., Tonshoff H.K., Luttervelt C.A., and van Khairy A.B. Advanced techniques for Die and Mold manufacturing. Annals of the CIRP 42 2 (1993) 707-716
4. Aspinwall D.K., Dewes R.C., Lee H.G., and Simao J. Electrical discharge surface alloying of Ti and Fe workpiece materials using refractory powder compact electrodes and Cu wire. Annals of the CIRP 52 1 (2003) 151-160
5. Bai C.-Y., and Koo C.-H. Effects of kerosene or distilled water as dielectric on electrical discharge alloying of superalloy Haynes 230 with Al-Mo composite electrode. Surface & Coatings Technology 200 (2006) 4127-4135
6. Barash M.M., and Kahlon C.S. Experiments with electric spark toughening. International Journal of Machine Tool Design & Research 4 (1965) 1-8
7. Bruyn H.E.D. Slope control-a great improvement in spark erosion. Annals of the CIRP 16 (1968) 183-186
8. Cao G., Zhao W., Wang Z., and Guo Y. Instantaneous fabrication of tungsten micro-electrode based on single electrical discharge. Journal of Materials Processing Technology 168 (2005) 83-88
9. Chen Y.F., Chow H.M., Lin Y.C., and Lin C.T. Surface modification using semi-sintered electrodes on electrical discharge machining. International Journal of Advanced Manufacturing Technology 36 (2008) 490-500
10. Crookall J.R., and Heuvelman C.J. Electro-discharge machining-the state of the art. Annals of the CIRP 20 1 (1971) 113-120
11. Curodeau A., Marceau L.F., Richard M., and Lessard J. New EDM polishing and texturing process with conductive polymer electrodes. Journal of Materials Processing Technology 159 (2005) 17-26
12. Eubank P.T., Patel M.R., Barrufet M.A., and Bozkurt B. Theoretical model of the electrical discharge machining process - III, the variable mass, cylindrical plasma model. Journal of Applied Physics 73 11 (1993) 7900-7909
13. Fredriksson G., and Hogmark S. Influence of dielectric temperature in EDM of hot worked tool steel. Surface Engineering 11 4 (1995) 324-330
14. Fuller J.E. Electrical Discharge Machining. ASM Machining Handbook vol. 16 (1996) pp. 557-564
15. Furutani K., Saneto A., Takezawa H., Mohri N., and Miyake H. Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid. Precision Engineering 25 (2001) 138-144
16. Furutani K., and Shimizu Y. Experimental analysis of deposition process of lubricant surface by EDM with molybdenum disulphide powder suspended in working oil. Proceedings of the American Society for Precision Engineering 30 (2003) 547-550
17. Gangadhar A., Shunmugam M.S., and Philip P.K. Surface modification in electrodischarge processing with powder compact tool electrode. Wear 143 (1991) 45-55
18. Ho K.H., and Newman S.T. State of the art electrical discharge machining. International Journal of Machine Tools & Manufacture 43 (2003) 1287-1300
19. Jameson E.C. Description and Development of Electrical Discharge Machining (2001), Society of Manufacturing Engineers, Dearbern, Michigan, USA
20. Jeswani M.L., and Basu S. Electron microprobe study of deposition and diffusion of tool material in electrical discharge machining. International Journal of Production Research 17 1 (1976) 1-14
21. Jeswani M.L. Effect of addition of graphite powder to kerosene used as a dielectric fluid in electrical discharge machining. Wear 70 (1981) 133-139
22. Kansal H.K., Singh S., and Kumar P. Application of Taguchi method for optimization of powder mixed electric discharge machining. International Journal of Management and Manufacturing Technology 7 (2005) 329-341 Nos. 2/3/4
23. Klocke F., Lung D., Antonoglou G., and Thomaidis D. The effects of powder suspended dielectrics on the thermal influenced zone by electrodischarge machining with small discharge energies. Journal of Material Processing Technology 149 (2004) 191-197
24. Koshy G., Philip P.K., and Geddam A. Hardening of surface layers using electric discharge techniques. Proceedings of the 11th AIMTDR Conference. IIT, Madras (1983) 315-319
25. Kozak J., Rozenek M., and Dabrowski L. Study of electrical discharge machining using powder-suspended working media. Journal of Engineering Manufacture, Proceedings of the Instrumental Mechanic Engineers 217 (2003) 1597-1602 part B
26. Kruth J.P. Rapid prototyping, a new application of physical and chemical processes for material accretion manufacturing. Proceedings of the ISEM-XI (1995) 3-28
27. Kruth J.P., Stevens L., Froyen L., and Lauwers B. Study on the white layer of a surface machined by die sinking electro-discharge machining. Annals of the CIRP 44 1 (1995) 169-172
28. Kruth J.P., Tonshoff H.K., and Klocke F. Surface and sub-surface quality in material removal process for tool making. Proceedings of the ISEM-12 (1998) 33-64
29. Kunieda M., and Yoshida M. Electric discharge machining in gas. Annals of the CIRP 46 1 (1997) 143-146
30. Kuneida M., Lauwers B., Rajurkar K.P., and Schumacher B.M. Advancing EDM through fundamental insight into the process. Annals of CIRP 54 2 (2005) 599-622
31. Kuppan P., Rajadurai A., and Narayanan S. Experimental investigation into electrical discharge deep hole drilling of Inconel 718 using graphite electrode. 1st International and 22nd AIMTDR Conference. IIT, Roorkee (2006) 923-928
32. Lahiri B.N., Mukherjee S.K., and Mullick B.K. Loss of energy in pyrolysis of dielectric in EDM process. Journal of Institution of Engineers (I) 62 (1981) 66-69 pt ME2
33. Lazarenko, B.R., 1943. To invert the effect of wear on electric power contacts. Dissertation of The All-Union Institute for Electro Technique in Moscow/CCCP (in Russian).
34. Lee H.G., Simao J., Aspinwall D.K., Dewes R.C., and Voice W. Electrical discharge surface alloying. Journal of Materials Processing Technology 149 (2004) 334-340
35. Lee L.C., Lim L.C., Narayanan V., and Venkatesh V.C. Quantification of surface damage of tool steels after EDM. International Journal of Machinery Tools & Manufacture 28 4 (1988) 359-372
36. Levy G.N., and Ferroni B. Planetary spark erosion-applications and optimization. Proceedings of the 16th MTDR Conference (1975) 291-297
37. Li L., Wong Y.S., Fuh J.Y.H., and Lu L. EDM performance of TiC/copper based sintered electrodes. Materials and Design 22 (2001) 669-678
38. Lin Y.C., Yan B.H., and Huang F.Y. Surface improvement using a combination of electrical discharge machining with ball burnish machining based on the Taguchi method. International Journal of Advanced Manufacturing Technology 18 (2001) 673-682
39. Lin Y.C., Yan B.H., and Huang F.Y. Surface modification of Al-Zn-Mg aluminum alloy using the combined process of EDM with USM. Journal of Materials Processing Technology 115 (2001) 359-366
40. Marafona J., and Wykes C. A new method of optimizing material removal rate using EDM with copper tungsten electrodes. International Journal of Machine Tools & Manufacture 40 2 (2000) 153-164
41. McGeough J.A. Advanced Methods of Machining. 1st ed. (1988), Chapman and Hall, USA ISBN 0-412-31970-5
42. Miyake H., Imai A., Goto A., Saito N., and Mohri N. Improvement of tool life through surface modification by electrical discharge machining. Proceedings of the ISEM-12 (1998) 261-270
43. Miyazaki T., Yoshioka S., Kimura T., and Kinoshita N. Surface modification of steel by a small diameter plasma arc. Annals of CIRP 44 1 (1995) 161-164
44. Mohri N., Saito N., and Tsunekawa Y. Metal surface modification by electrical discharge machining with composite electrodes. Annals of the CIRP 42 1 (1993) 219-222
45. Mohri N., Takezawa H., Furutani K., Ito Y., and Sata T. A new process of additive and removal machining by EDM with a thin electrode. Annals of CIRP 40 1 (2000) 123-126
46. Mohri N., Fukusima Y., Fukuzawa Y., Tani T., and Saito N. Layer generation process on workpiece in electrical discharge machining. Annals of the CIRP 52 1 (2003) 157-160
47. Moro T., Goto A., Mohri N., Saito N., Matsukawa K., and Miyake H. Surface modification process by electrical discharge machining with TiC semi-sintered electrode. Journal of Japanese Society of Precision Engineering 67 1 (2001) 114-119
48. Narumiya H., Mohri N., Saito N., Ootake H., Tsunekawa Y., Takawashi T., and Kobayashi K. EDM by powder suspended working fluid. Proceedings of the ISEM-9. Nagoya, Japan, 5-8 (1989)
49. Okada A., Uno Y., and Hirao K. Formation of hard layer by EDM with carbon powder mixed fluid using titanium electrode. Proceedings of the International Conference on Progress of Machining Technology (2000) 464-469
50. Panda D.K., and Bhoi R.K. Experimental investigation of relative erosion of electrodes in electrical discharge machining. Proceedings of the 1st International and 22nd AIMTDR Conference. IIT, Roorkee (2006) 929-934
51. Pantelis D.I., Vaxevanidis N.M., Houndri A.E., Dumas P., and Jeandin M. Investigation into application of electrodischarge machining as steel surface modification technique. Surface Engineering 14 1 (1998) 55-61
52. Patel M.R., Barrufet M.A., and Eubank P.T. Theoretical model of the electrical discharge machining process - II, the anode erosion model. Journal of Applied Physics 66 9 (1989) 4104-4111
53. Patowari P.K., Mishra U.K., Saha P., and Mishra P.K. Surface modification of C-40 steel using WC-Cu P/M green compact electrodes in EDM. Proceedings of the 1st International and 22nd AIMTDR Conference. IIT, Roorkee, India (2006) 875-879
54. Pecas P., and Henriques E. Influence of silicon powder-mixed dielectric on conventional electrical discharge machining. International Journal of Machine Tools & Manufacture 43 (2003) 1465-1471
55. Pecas P., and Henriques E. Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric. International Journal of Advanced Manufacturing Technology 37 (2008) 1120-1132
56. Rehbein W., Schulze H.P., Mecke K., Wollenberg G., and Storr M. Influence of selected groups of additives on breakdown in EDM sinking. Journal of Materials Processing Technology 149 (2004) 58-64
57. Roethel F., and Garbajs V. Contributions to the micro-analysis of spark eroded surfaces. Annals of the CIRP 25 1 (1976) 135-140
58. Samuel M.P., and Philip P.K. Powder metallurgy tool electrodes for electrical discharge machining. International Journal of Machine Tools & Manufacture 37 11 (1997) 1625-1633
59. Schumacher B.M. EDM technology for precision workpieces with excellent surface quality. Proceedings of the ISEM-7 (1983) 124-135
60. Schumacher B.M. After 60 years of EDM, the discharge process remains still disputed. Journal of Materials Processing Technology 149 (2004) 376-381
61. Shankar N.U., and Krishnan A. Polarity effect in spark erosion machining. Indian Journal of Technology 17 9 (1979) 363-364
62. Shankar P., Jain V.K., and Sundararajan T. Analysis of spark profiles during EDM process. Machinery Science & Technology 1 2 (1997) 195-217
63. Shunmugam M.S., Philip P.K., and Gangadhar A. Improvement of wear resistance by EDM with tungsten carbide powder metallurgy electrode. Wear 171 (1994) 1-5
64. Simao J., Aspinwall D., El-Menshawy F., and Meadows K. Surface alloying using PM composite electrode materials when electrical discharge texturing hardened AISI D2. Journal of Materials Processing Technology 127 (2002) 211-216
65. Simao J., Lee H.G., Aspinwall D.K., Dewes R.C., and Aspinwall E.M. Workpiece surface modification using electrical discharge machining. International Journal of Machine Tools & Manufacture 43 (2003) 121-128
66. Singh S., Kansal H.K., and Kumar P. Parametric optimization of powder mixed electrical discharge machining by response surface methodology. Journal of Materials Processing Technology 169 3 (2005) 427-436
67. Soni J.S., and Chakraverty G. Effect of Electrode Material Properties on Surface Roughness & Dimensional Accuracy in Electric Discharge Machining of High carbon High chromium Die Steel. Journal of Institution of Engineers (I) - PR (1995) 76
68. Soni J.S., and Chakraverti G. Experimental investigation on migration of material during EDM of T 215 Cr12 die steel. Journal of Materials Processing Technology 56 (1996) 439-451
69. Toren M., Zvirin Y., and Winograd Y. Melting and evaporation phenomena during electrical erosion. Transactions of ASME Journal of Heat Transfer 97 (1975) 576-581
70. Tsai H.C., Yan B.H., and Huang F.Y. EDM performance of Cr/Cu-based composite electrodes. International Journal of Machine Tools & Manufacture 43 (2003) 245-252
71. Tsai K.M., and Wang P.J. Predictions on surface finish in electrical discharge machining based upon neural network models. International Journal of Machine Tools & Manufacture 41 10 (2001) 1385-1403
72. Tsukahara H., and Sone T. Surface hardening of titanium using EDM process. Titan Japan 48 2 (2000) 47-49
73. Tsunekawa Y., Okumiya M., Mohri N., and Takahashi I. Surface modification of aluminum by electrical discharge alloying. Materials Science and Engineering A174 (1994) 193-198
74. Tzeng Y., and Chen F. Investigation into some surface characteristics of electrical discharge machined SKD-11 using powder-suspension dielectric oil. Journal of Materials Processing Technology 170 (2005) 385-391
75. Tzeng Y.F., and Lee C.Y. Effect of powder characteristics on electrodischarge machining efficiency. International Journal of Advanced Manufacturing Technology 17 8 (2001) 586-592
76. Venkatesh V.C., and Parasnis S. Surface transformation in high speed steel after electro discharge machining. Proceedings of the 5th AIMTDR Conference. IIT, Roorkee, India (1972) 639-649
77. Wang Z.L., Fang Y., Wu P.N., Zhao W.S., and Cheng K. Surface modification process by electrical discharge machining with a Ti powder green compact electrode. Journal of Materials Processing Technology 129 (2002) 139-142
78. Wong Y.S., Lim L.C., and Lee L.C. Effect of flushing on electro-discharge machined surfaces. Journal of Materials Processing Technology 48 (1995) 299-305
79. Wong Y.S., Lim L.C., Rahuman I., and Tee W.M. Near mirror-finish phenomenon in EDM using powder-mixed dielectric. Journal of Materials Processing Technology 79 (1998) 30-40
80. Wu K.L., Yan B.H., Huang F.Y., and Chen S.C. Improvement of surface finish on SKD steel using electro-discharge machining with aluminum and surfactant added dielectric. International Journal of Machine Tools & Manufacture 45 (2005) 1195-1201
81. Yan B.H., Lin Y.C., and Huang F.Y. Surface modification of Al-Zn-Mg alloy by combined electrical discharge machining with ball burnish machining. International Journal of Machine Tools & Manufacture 42 (2002) 925-934
82. Yan B.H., Tsai H.C., and Huang F.Y. The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. International Journal of Machine Tools & Manufacture 45 (2005) 194-200
83. Zhao W.S., Meng Q.G., and Wang Z.L. The application of research on powder mixed EDM in rough machining. Journal of Materials Processing Technology 129 (2002) 30-33
84. Zimanyi J. Photometric determination of the spatial and chronological structure variations of the discharge by spark erosion metalworking. Annals of the CIRP 24 1 (1975) 89-94