NDLI: Fabrication of texturing tool to produce array of square holes for EDM by abrasive water jet machining

Content Provider	Springer Nature Link
Author	Pal, Vijay Kumar Choudhury, S. K.
Copyright Year	2015
Abstract	In the present work, a novel abrasive water jet machining (AWJM)-based tool fabrication strategy has been proposed and implemented to make electrical discharge machining (EDM) tools for large-area texturing. The novelty of the work lies in the path strategy proposed for jet movement that moves along two raster paths placed at 90° to each other. By using this path strategy, micro-tools of EDM for machining arrays of square holes were fabricated by AWJ milling process. Based on selected parameters of AWJ process (step-over, traverse speed, path strategy), micro-tools were fabricated on brass and copper sheets. The quality of the kerf obtained during machining by AWJ is conventionally measured using the taper angle. It is explained here how this kind of measurements fall short of quantifying the quality of blind features generated in modern applications of AWJM. These generated features can be accurately measured using highly sensitive techniques of 3D optical profilometer. Based on these measurements, a model based on two performance indices, namely Area-Based Performance Index (API) and Curve-Based Performance Index (CPI) were introduced to analyse such fabricated tools. The technology of large-area texturing to make the overall process fast, by producing high-quality tools in less time, has been demonstrated by using the proposed methodology. Performance of such fabricated tools was investigated by performing experiments on EDM machine. Arrays of square blind holes (texture) were made on stainless steel and Ti-6Al-4V alloy sheet using Die sinking mode EDM. The depth of texture was measured through 3D optical profilometer and was found to be in the range of 10 to 100 μm. The dimensions of textured features were found deviating from the tool dimension due to taper present on sidewalls of micro-tools produced through AWJM.
Starting Page	2061
Ending Page	2071
Page Count	11
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	85
Issue Number	9-12
e-ISSN	14333015
Language	English
Publisher	Springer London
Publisher Date	2015-10-12
Publisher Place	London
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	AWJM Path strategy API CPI Texturing EDM Electrode (tool) Industrial and Production Engineering Production Mechanical Engineering Computer-Aided Engineering (CAD, CAE) and Design
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

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4	Project PI / Joint PI	Principal Investigator and Joint Principal Investigators of the project	Dr. B. Sutradhar bsutra@ndl.gov.in Prof. Saswat Chakrabarti will be added soon
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