Search Results (38)

Electric discharge machining processes are prominent in the fastest-growing industries because of their accuracy, achievable complex workpiece shapes, and cost-effectiveness. Furthermore, the machining of high-quality difficult-to-machine alloys is becoming critical in the aerospace, manufacturing, and defence industries. While the optimisation of EDM parameters is essential for improving machining outcomes, it is also important to consider the trade-offs between different performances metrics, such as material removal rate and part accuracy. Part accuracy in terms of dimensional and geometric deviations from nominal values was rarely considered in the literature, if not by the authors. Balancing these factors remains a challenge in the field of EDM. Therefore, this work aims to carry out a multi-objective optimisation of both MRR and part accuracy. A Ni-based alloy (Inconel-625) was used that is widely used in creep-resistant turbine blades and vanes and turbine disks in gas turbine engines for aerospace and defence industries. Four performance indices were optimised simultaneously: two related to the performance of the EDM process and two connected with the form deviations of the manufactured surfaces. Multi-hole copper electrodes having different diameters and three process parameters were varied during the experimental tests. Grey relational analysis and the Adaptive Neuro-Fuzzy Inference System method were used for optimisation. Grey relational analysis found that the following values of the process parameter—0.16 mm of multi-hole electrode diameter, 12 Amperes of Peak current, 200 µs of pulse on time and 0.2 kg/m² as dielectric pressure—produce the optimal performance, i.e., a material removal rate of 0.099 mm³/min, an electrode wear rate of 0.0002 g/min, a circularity deviation of 0.0043 mm and a cylindricity deviation of 0.027 mm. From the experimental examination using multi-hole electrodes, it is concluded that the material removal rate increases and the electrode wear rate decreases because of the availability of higher spark discharge areas between the electrode and work material interface. The Adaptive Neuro-Fuzzy Inference System models showed minimum mean percentage error and, therefore, better performance in comparison with regression models. Full article

Efficient coal grinding is a crucial aspect of the energy and mining industries. However, traditional grinding methods are known to be energy-intensive and cause significant wear on equipment as well as negative environmental impacts due to the release of small particles that can harm air quality and affect human health. In response to these challenges, we are conducting research to develop an electric pulse device for coal grinding. This device will use high-voltage discharges in a liquid medium to create shock waves that selectively destroy coal particles while minimizing mechanical damage. The electric pulse installation consisted of a control unit (for monitoring the operating modes of the installation), a generator (for converting the AC input voltage into DC output voltage), a capacitor (for energy storage), a protection system (for shutting down the installation in cases when a voltage exceeding the set safe operating discharge voltage occurs on the capacitor), a spark gap (forming a gap consisting of two conductive hemispherical electrodes separated by an air gap, designed to form an electric spark between conductors), and an electric pulse grinding device. The input material for each experiment had consistent parameters: the coal particles were diameter 8–10 mm and weighed 400 g. Coal was processed using the electric pulse method with various voltage values, numbers of pulses, capacitor capacities, and pulse frequencies. The yield of the final product depended on these parameters, and effective settings for producing coal powder were identified. The research results demonstrate that a flat metal mesh plate is effective as the negative electrode in the electric pulse grinding device. Full article

Electrostatic techniques have introduced innovative approaches to devise efficient tools for pest control across various categories, encompassing pathogens, insects, and weeds. The focus on electric discharge technology has proven pivotal in establishing effective methods with simple device structures, enabling cost-effective fabrication using readily available materials. The electric discharge-generating devices can be assembled using commonplace conductor materials, such as ordinary metal nets linked to a voltage booster and a grounded electric wire. The strategic pairing of charged and grounded conductors at specific intervals generates an electric field, leading the charged conductor to initiate a corona discharge in the surrounding space. As the applied voltage increases, the corona discharge intensifies and may eventually result in an arc discharge due to the breakdown of air when the voltage surpasses the insulation resistance limit. The utilization of corona and arc discharges plays a crucial role in these techniques, with the corona-discharging stage creating (1) negative ions to stick to pests, which can then be captured with a positively charged pole, (2) ozone gas to sterilize plant hydroponic solutions, and (3) plasma streams to exterminate fungal colonies on leaves, and the arc-discharging stage projecting electric sparks to zap and kill pests. These electric discharge phenomena have been harnessed to develop reliable devices capable of managing pests across diverse classes. In this review, we elucidate past achievements and challenges in device development, providing insights into the current status of research. Additionally, we discuss the future directions of research in this field, outlining potential avenues for further exploration and improvement. Full article

Eggs are a highly nutritious food; however, those are also fragile and susceptible to cracks, which can lead to bacterial contamination and economic losses. Traditional methods for detecting cracks, particularly in processed eggs, often fall short due to changes in the eggs’ physical properties during processing. This study was aimed at developing a novel device for detecting egg cracks using electric discharge phenomena. The system was designed to apply a high-voltage electric field to the eggs, where sparks were generated at crack locations due to the differences in electrical conductivity between the insulative eggshell and the more conductive inner membrane exposed by the cracks. The detection apparatus consisted of a custom-built high-voltage power supply, flexible electrode pins, and a rotation mechanism to ensure a complete 360-degree inspection of each egg. Numerical simulations were performed to analyze the distribution of the electric field and charge density, confirming the method’s validity. The results demonstrated that this system could efficiently detect cracks in both raw and processed eggs, overcoming the limitations of existing detection technologies. The proposed method offers high precision, reliability, and the potential for broader application in the inspection of various poultry products, representing a significant advancement in food safety and quality control. Full article

Developing long-lasting humidity sensors is essential for sustainable advancements in nanotechnology. Prolonged exposure to high humidity can cause sensors to drift from their calibration points, leading to long-term accuracy issues. Our research aims to develop a fabrication method that produces stable sensors capable of withstanding the environmental challenges faced by humidity sensors. Traditional iron-based nanoparticles often require complex treatments, such as chemical modification or thermal annealing, to maintain their properties. This study introduces a novel, one-step synthesis method for iron-based thin films with exceptional stability. The synthesized films were thoroughly characterized using X-ray photoelectron spectroscopy (XPS) to evaluate their phase stability and nitride formation. The method proposed in this study employs an electrical sparking discharge process within a pure nitrogen atmosphere under a 0.2 T magnetic field, producing thin films composed of nanoparticles approximately 20 nm in size. The resulting films demonstrate superior performance in humidity sensing applications compared to conventional methods. This straightforward and efficient approach offers a promising path toward robust and sustainable humidity sensors. Full article

Water pollution with microplastics has become a significant concern. Conventional treatment methods have proven ineffective, and alternatives are being explored. Herein, we assess the degradation efficiency of polystyrene (PS) by measuring its nanosecond discharge in air in contact with water. Its discharge is characterized during processing, and a transition from streamer-like to spark-like discharge occurs due to the increased electrical conductivity of water. Experiments are conducted at different frequencies, and the highest degradation is achieved at 10 kHz; an 83% polystyrene weight loss is recorded after 5 min of processing. The optical spectra of the discharge show no evidence of C-species, and an FTIR analysis of the processed polystyrene reveals no structural modifications. An NMR analysis shows the presence of ethylbenzene in water. Finally, a mechanism of PS degradation is proposed. Full article

Titanium-based composite materials arouse interest in fields like aerospace, transportation, medicine, and other applications. This research project presents the analysis of phase composition of sintered Ti-Al-C composite materials under high voltage electrical discharge. The new technology, described in the previous work of the authors, allows to synthesise the composites containing various intermetallics, carbides, and nanostructures. The samples of Ti-Al-C powder composites were tested by SEM, Raman spectroscopy, and XRD. It was determined that the treatment of the powder by high voltage electrical discharge (HVED) and further sintering at high temperatures using the spark plasma sintering (SPS) method encouraged the formation of the intermetallic reinforcing phases, carbides, and different nanocarbon structures like graphene and fullerenes, as well as pure graphite. Intermetallic phases and nanocarbon structures improved the mechanical and physical properties of the composites. By using the experimental methods mentioned above, the phase composition of Ti-Al-C powder composites obtained at different sintering temperatures was determined. It was revealed that new composite materials produced by HVED and further SPS were rich with carbides, intermetallics, and MAX phases. Therefore, the carbon nanostructures (graphene and graphite) were detected existing in the structure of the produced new Ti-Al-C composite material. All these reinforcing particles improved the microstructure and the mechanical properties of the composites, as was proved in the previous research by the authors and by the different scientific resources. This project is a pilot experimental work, therefore not all peaks of Raman and XRD were detected; they will be analysed in future works. Full article

Electrical Discharge Machining (EDM) is a machining method commonly used to produce complex shapes and deep holes by eroding hard metals with an electric arc. There is a growing demand for process simulation using finite element models in order to improve the quality and efficiency of EDM, to reduce costs, to improve resource efficiency, and to facilitate its application in critical areas such as aerospace and mechanical engineering. Finite element models have greatly improved the prediction accuracy of EDM processes, simulated complex hybrid machining processes, and provided important guidance for the optimization of EDM processes. This paper systematically reviews the research progress of finite element modeling for EDM. Finite element method modeling is evaluated mainly in terms of four indicators: material removal rate, surface roughness, tool wear ratio, and recast layer thickness. Firstly, the importance and application of EDM are described, and the EDM finite element method modeling and its advantages are summarized. Then, the single-spark simulation model and the multi-spark simulation model of EDM are compared and discussed. Among the mainstream finite element models, the prediction error of the material removal rate for single-spark simulation ranges from 8.2% to 14.75%, while the prediction error of the recast layer thickness for multi-spark simulation can be as low as 1.98%. Finally, the applications of finite element modeling in EDM hybrid machining processes’ performance prediction and new material machining are summarized, and future research directions and trends in EDM finite element modeling are predicted. Full article

The most effective and cutting-edge method for achieving a 0.004 mm precision on a typical material is to employ die-sinking electrical discharge machining (EDM). The material removal rate (MRR), tool wear rate (TWR), residual stresses, and crater depth were analyzed in the current study in an effort to increase the productivity and comprehension of the die-sinking EDM process. A parametric design was employed to construct a two-dimensional model, and the accuracy of the findings was verified by comparing them to prior research. Experiments were conducted utilizing the EDM machine, and the outcomes were assessed in relation to numerical simulations of the MRR and TWR. A significant temperature disparity that arises among different sections of the workpiece may result in the formation of residual strains throughout. As a consequence, a structural model was developed in order to examine the impacts of various stress responses. The primary innovations of this paper are its parametric investigation of residual stresses and its use of Haynes 25, a workpiece material that has received limited attention despite its numerous benefits and variety of applications. In order to accurately forecast the output parameters, a deep neural network model, more precisely, a multilayer perceptron (MLP) regressor, was utilized. In order to improve the precision of the outcomes and guarantee stability during convergence, the L-BFGS solver, an adaptive learning rate, and the Rectified Linear Unit (ReLU) activation function were integrated. Extensive parametric studies allowed us to determine the connection between key inputs, including the discharge current, voltage, and spark-on time, and the output parameters, namely, the MRR, TWR, and crater depth. Full article

As a novel microfabrication method, electrochemical discharge machining has remarkable effects on the forming and processing of brittle and hard materials and non-conductive materials, but little research has been done on the electrochemical discharge mode in the jet state. To fulfil the potential of this technology, innovative research on the discharge characteristics and mechanism of electrochemical discharge machining in the jet mask is proposed. A high-speed camera observation experiment was set up to record the process of the jet flow column discharge formation and penetration. Changes in the electric field of the electrolytic jet channel were analysed by simulation software, and the morphology of the machined micro-pits was observed using a microscope. A mathematical derivation of the dielectric electric field in the gas–liquid two-phase jet column reveals the mechanism of discharge channel formation in the jet state. The experiments show that when the processing voltage is 400 V, a stable continuous spark appears, realizing the unique characteristics of a large-gap long-distance discharge and a flat small circle-shaped discharge mark produced at the bottom of the crater. The actual field strength within the bubble of this model obtained by mathematical derivation is approximately 61.5 kV/cm greater than the critical field strength for air bubble breakdown in the standard state, where bubble breakdown occurs in the discharge. Full article

In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted. Full article

Dispersion-hardened materials based on TiC–AlnCn are alloys with high heat resistance, strength, and durability that can be used in aircraft and rocket technology as a hard lubricant. The titanium-rich composites of the Ti–Al–C system were synthesized via the spark plasma sintering process. Composite powder with 85% of Ti, 15% of Al, and MAX-phases was processed using high-voltage electrical discharge in kerosene at a specific energy of 25 MJ kg⁻¹ to obtain nanosized particles. This method allows us to analyze the most efficient, energy saving, and less waste-generating technological processes producing materials with improved mechanical and physical properties. An Innova test indentation machine was used to determine the hardness of the synthesized composites. The microhardness of Ti–Al–C system samples was determined as approximately 500–600 HV. Scanning electron microscopy and energy-dispersive X-ray spectroscopy were performed to identify the hard titanium matrix reinforced by intermetallic phases and the clusters of carbides. Three types of reinforcing phases were detected existing in the composites—TiC, Al₄C₃, and Al₃Ti, as well as a matrix consisting of α- and β-titanium. The lattice parameters of all phases detected in the composites were calculated using Rietveld analysis. It was determined that by increasing the temperature of sintering, the amount of aluminum and carbon increases in the carbides and intermetallic phases, while the amount of titanium decreases. Full article

This paper provides an overview of modern research on magnetoplasma methods of influencing gas-dynamic and plasma flows. The main physical mechanisms that control the interaction of plasma discharges with gaseous moving media are indicated. The ways of organizing pulsed energy input, characteristic of plasma aerodynamics, are briefly described: linearly stabilized discharge, magnetoplasma compressor, capillary discharge, laser-microwave action, electron beam action, nanosecond surface barrier discharges, pulsed spark discharges, and nanosecond optical discharges. A description of the physical mechanism of heating the gas-plasma flow at high values of electric fields, which are realized in high-current and nanosecond (ultrafast heating) electric discharges, is performed. Methods for magnetoplasma control of the configuration and gas-dynamic characteristics of shock waves arising in front of promising and advanced aircraft (AA) are described. Approaches to the control of quasi-stationary separated flows, laminar–turbulent transitions, and static and dynamic separation of the boundary layer (for large PA angles of attack) are presented. Full article

This study developed an unattended electric weeder (UEW) to control floor weeds in an orchard greenhouse. The UEW was a motor-driven dolly equipped with a spark exposer. The spark exposer was constructed by applying an alternating voltage (10 kV) to a conductor net (expanded metal net). The charged conductor net (C-CN) discharged into the surrounding space. Wild oat and white clover were used as test weed species. Weed seedlings growing on the floor were grounded by the biological conductor and were subjected to a spark from the C-CN when they reached the discharge space. The spark-exposed seedlings were singed and shrunk instantaneously. In the present experiment, the UEW was remotely controlled to move on the soil-cover metal nets, which were laid on the floor to make a flat surface, in a stop-and-go manner, and to eject a spark to the weed seedlings that emerged from the floor. All of the mono- and dicotyledonous weed seedlings, which had been artificially sown on the floor, were completely eradicated using this method. Thus, this study provides an experimental basis for developing an unattended technique for controlling floor weeds in an orchard greenhouse. Full article

Germanium–tin nanoparticles are promising materials for near- and mid-infrared photonics thanks to their tunable optical properties and compatibility with silicon technology. This work proposes modifying the spark discharge method to produce Ge/Sn aerosol nanoparticles during the simultaneous erosion of germanium and tin electrodes. Since tin and germanium have a significant difference in the potential for electrical erosion, an electrical circuit damped for one period was developed to ensure the synthesis of Ge/Sn nanoparticles consisting of independent germanium and tin crystals of different sizes, with the ratio of the atomic fraction of tin to germanium varying from 0.08 ± 0.03 to 0.24 ± 0.07. We investigated the elemental and phase composition, size, morphology, and Raman and absorbance spectra of the nanoparticles synthesized under different inter-electrode gap voltages and the presence of additional thermal treatment directly in a gas flow at 750 °C. The research shows that the in-flow thermal treatment of aerosol-agglomerated nanoparticles produced special individual bicrystalline Janus Ge/Sn nanoparticles with an average size of 27 nm and a decreasing absorption function with a changing slope at 700 nm. Full article