A comparative experimental investigation of deep-hole micro-EDM drilling capability for cemented carbide (WC-Co) against austenitic stainless steel (SUS 304)

Microelectro-discharge machining (micro-EDM) has become a widely accepted non-traditional material removal process for machining difficult-to-cut but conductive materials effectively and economically. The present study aims to investigate the feasibility of machining deep microholes in two difficult-to-cut materials: cemented carbide (WC-Co) and austenitic stainless steel (SUS 304) using the micro-EDM drilling. The effect of discharge energy and electro-thermal material properties on the performance of the two work materials during the micro-EDM drilling has also been investigated. The micro-EDM drilling performance of two materials has been assessed based on the quality and accuracy of the produced microholes, machining stability, material removal rate (MRR), and electrode wear ratio. The results show that deep-hole micro-EDM drilling is technically more feasible in WC-Co as it offers microholes with smooth and burr-free surfaces at the rim in addition to improved circularity and lower overcut than those provided by SUS 304. Moreover, WC-Co exhibits better machinability during the deep-hole micro-EDM drilling, providing relatively higher MRR and stable machining.

[1]  P. Marshall,et al.  Austenitic Stainless Steels , 1984 .

[2]  J. McGeough.  Advanced Methods Of Machining , 1988 .

[3]  Scandvik coromant.  Modern Metal Cutting : a practical handbook , 1994 .

[4]  N. Mohri,et al.  Electrode Wear Process in Electrical Discharge Machinings , 1995 .

[5]  J. S. Soni,et al.  Experimental investigation on migration of material during EDM of die steel (T215 Cr12) , 1996 .

[6]  Traugott E. Fischer,et al.  Sliding wear of conventional and nanostructured cemented carbides , 1997 .

[7]  Biing-Hwa Yan,et al.  Micro-hole machining of carbide by electric discharge machining , 1999 .

[8]  Sture Hogmark,et al.  Grooving wear of single-crystal tungsten carbide , 1999 .

[9]  Ajit Singh,et al.  A thermo-electric model of material removal during electric discharge machining , 1999 .

[10]  Takahisa Masuzawa,et al.  State of the Art of Micromachining , 2000 .

[11]  S. H. Lee,et al.  Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide , 2001 .

[12]  Kui Liu,et al.  Ductile cutting of tungsten carbide , 2001 .

[13]  D. O’Sullivan,et al.  Machinability of austenitic stainless steel SS303 , 2002 .

[14]  Paulo Carlos Kaminski,et al.  Micro hole machining by conventional penetration electrical discharge machine , 2003 .

[15]  Y. Wong,et al.  Investigation of micro-EDM material removal characteristics using single RC-pulse discharges , 2003 .

[16]  Mahmudur Rahman,et al.  A study on the machining of high-aspect ratio micro-structures using micro-EDM , 2003 .

[17]  Stephen T. Newman,et al.  State of the art electrical discharge machining (EDM) , 2003 .

[18]  Z. Tekiner,et al.  Investigation of the cutting parameters depending on process sound during turning of AISI 304 austenitic stainless steel , 2004 .

[19]  Yunn-Shiuan Liao,et al.  A study to achieve a fine surface finish in Wire-EDM , 2004 .

[20]  M. Rahman,et al.  A study of the cutting modes in the grooving of tungsten carbide , 2004 .

[21]  T. Masuzawa,et al.  An index to evaluate the wear resistance of the electrode in micro-EDM , 2004 .

[22]  Masanori Kunieda,et al.  Improvement of machining characteristics of micro-EDM using transistor type isopulse generator and servo feed control , 2004 .

[23]  I. Korkut,et al.  Determination of optimum cutting parameters during machining of AISI 304 austenitic stainless steel , 2004 .

[24]  Ramezanali Mahdavinejad,et al.  ED machining of WC-Co , 2005 .

[25]  Z. Katz,et al.  Analysis of micro-scale EDM process , 2005 .

[26]  Biing-Hwa Yan,et al.  A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications , 2005 .

[27]  F. Amorim,et al.  The influence of generator actuation mode and process parameters on the performance of finish EDM of a tool steel , 2005 .

[28]  Masanori Kunieda,et al.  Advancing EDM through fundamental insight into the process , 2005 .

[29]  Gwo-Lianq Chern,et al.  Study on vibration-EDM and mass punching of micro-holes , 2006 .

[30]  Chang Ching-Kao,et al.  The optimal cutting-parameter selection of heavy cutting process in side milling for SUS304 stainless steel , 2007 .

[31]  Yahya Isik,et al.  Investigating the machinability of tool steels in turning operations , 2007 .

[32]  José Duarte Marafona,et al.  Black layer characterisation and electrode wear ratio in electrical discharge machining (EDM) , 2007 .

[33]  Duc Truong Pham,et al.  An investigation of tube and rod electrode wear in micro EDM drilling , 2007 .

[34]  Kimiyuki Mitsui,et al.  A new approach on the determination of ease of machining by EDM processes , 2008 .

[35]  Mahmudur Rahman,et al.  A Comparative Study of Transistor and RC Pulse Generators for Micro-EDM of Tungsten Carbide , 2008 .

[36]  A. Khan.  Electrode wear and material removal rate during EDM of aluminum and mild steel using copper and brass electrodes , 2008 .

[37]  Y. Wong,et al.  A study on the quality micro-hole machining of tungsten carbide by micro-EDM process using transistor and RC-type pulse generator , 2009 .