A novel servo-stabilized electromagnetic levitation formicro-EDM processing and its feasibility analysis. (May 2023)

• Record Type: Journal Article
• Authors: Kumar, Deepak; Sisodiya, Mangal Singh; Bajpai, Vivek
• Is Part Of: Proceedings of the Institution of Mechanical Engineers. Volume 237:Number 6/7(2023)
• Page Start: 862
• Page End: 872
• Publication Date: 2023-05
• Subjects: Maglev-EDM -- actuator arm -- Nimonic alloy -- EDM oil -- V-I curve -- FESEM -- EDX; Mechanical engineering -- Periodicals; Engineering -- Management -- Periodicals; Manufacturing processes -- Periodicals; 629.8
• DOI: 10.1177/09544054221124473
• Languages: English
• ISSNs: 0954-4054

Abstract

The purpose of this paper is to evaluate the feasibility of a novel gap-controlled strategy for micro-EDM process using magnetic levitation. The tool is levitated and positioned accurately using a unique actuator arm. The actuator arm attained the required positioning accuracy in the thrust (Z) direction to ensure a uniform and smooth discharge free of arcing and short circuits. Experiments were carried out using a copper tool and EDM oil on Nimonic superalloy (Grade C-263). Material removal rate (79.26 µg/min), tool wear rate (19.75 µg/min), and average surface roughness (Ra = 1.196 µm) all proved the efficacy of the developed technology. Furthermore, the machining stability and average specific energy (1.7350 J/μg) were examined and compared to the experimental results of traditional EDM, as well as literature data. Maglev μ-EDM is substantially more stable than traditional EDM, according to a comparison of the current-voltage (V-I) curve. Microholes, micropores, recast layer, and other surface topographical features are detected in a low amount using FESEM. The bidirectional material movement and elemental diffusion are shown by elemental characterization using EDX analysis.