High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode
Electro-discharge drilling is a key technology for manufacturing sophisticated nozzles in a broad range of automotive and aerospace applications. The formation of debris in the working gap leads to arcs and short circuits on the lateral surface when state-of-the-art tool electrodes are used. As a re...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-10-01
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| Series: | Journal of Manufacturing and Materials Processing |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2504-4494/6/5/113 |
| _version_ | 1797472455741145088 |
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| author | Eckart Uhlmann Julian Polte Jan Streckenbach Ngoc Chuong Dinh Sami Yabroudi Mitchel Polte Julian Börnstein |
| author_facet | Eckart Uhlmann Julian Polte Jan Streckenbach Ngoc Chuong Dinh Sami Yabroudi Mitchel Polte Julian Börnstein |
| author_sort | Eckart Uhlmann |
| collection | DOAJ |
| description | Electro-discharge drilling is a key technology for manufacturing sophisticated nozzles in a broad range of automotive and aerospace applications. The formation of debris in the working gap leads to arcs and short circuits on the lateral surface when state-of-the-art tool electrodes are used. As a result, limited drilling depth, increased linear tool wear, and the conicity of boreholes are still challenges. In this work, a new approach for the passivation of the lateral surface of copper tool electrodes by oxidation is shown. The comparison with state-of-the-art tool electrodes showed a reduction in the erosion duration by 48% for machining hardened steel. Promising improvements could be achieved by the thermal oxidation of the tool electrodes with the aim of increasing the electrical resistivity of the lateral surface of the tool electrode. However, due to the loss of strength, the high oxide layer thickness, and the partial delamination of the oxide layer, further comprehensive investigations on the influence of the oxidation temperature need to be conducted. Future adjustments with lower oxidation temperatures will be carried out. |
| first_indexed | 2024-03-09T20:02:00Z |
| format | Article |
| id | doaj.art-855216effd5543cea129d939dc8c8292 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-09T20:02:00Z |
| publishDate | 2022-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-855216effd5543cea129d939dc8c82922023-11-24T00:42:25ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942022-10-016511310.3390/jmmp6050113High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool ElectrodeEckart Uhlmann0Julian Polte1Jan Streckenbach2Ngoc Chuong Dinh3Sami Yabroudi4Mitchel Polte5Julian Börnstein6Fraunhofer Institute for Production Systems and Design Technology IPK, Pascalstraße 8-9, 10587 Berlin, GermanyFraunhofer Institute for Production Systems and Design Technology IPK, Pascalstraße 8-9, 10587 Berlin, GermanyInstitute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587 Berlin, GermanyInstitute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587 Berlin, GermanyInstitute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587 Berlin, GermanyFraunhofer Institute for Production Systems and Design Technology IPK, Pascalstraße 8-9, 10587 Berlin, GermanyFraunhofer Institute for Production Systems and Design Technology IPK, Pascalstraße 8-9, 10587 Berlin, GermanyElectro-discharge drilling is a key technology for manufacturing sophisticated nozzles in a broad range of automotive and aerospace applications. The formation of debris in the working gap leads to arcs and short circuits on the lateral surface when state-of-the-art tool electrodes are used. As a result, limited drilling depth, increased linear tool wear, and the conicity of boreholes are still challenges. In this work, a new approach for the passivation of the lateral surface of copper tool electrodes by oxidation is shown. The comparison with state-of-the-art tool electrodes showed a reduction in the erosion duration by 48% for machining hardened steel. Promising improvements could be achieved by the thermal oxidation of the tool electrodes with the aim of increasing the electrical resistivity of the lateral surface of the tool electrode. However, due to the loss of strength, the high oxide layer thickness, and the partial delamination of the oxide layer, further comprehensive investigations on the influence of the oxidation temperature need to be conducted. Future adjustments with lower oxidation temperatures will be carried out.https://www.mdpi.com/2504-4494/6/5/113electrical discharge machiningsurface treatmentoxidation |
| spellingShingle | Eckart Uhlmann Julian Polte Jan Streckenbach Ngoc Chuong Dinh Sami Yabroudi Mitchel Polte Julian Börnstein High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode Journal of Manufacturing and Materials Processing electrical discharge machining surface treatment oxidation |
| title | High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode |
| title_full | High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode |
| title_fullStr | High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode |
| title_full_unstemmed | High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode |
| title_short | High-Performance Electro-Discharge Drilling with a Novel Type of Oxidized Tool Electrode |
| title_sort | high performance electro discharge drilling with a novel type of oxidized tool electrode |
| topic | electrical discharge machining surface treatment oxidation |
| url | https://www.mdpi.com/2504-4494/6/5/113 |
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