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1. INTRODUCTION
Nowadays industrial products with high performance and precise micro components
are required in many fields. For example, ultraprecise moulds are necessary to
produce lenses for digital cameras and motor cores for various kinds of motors. Micro
machining technology has therefore become an important issue in fabricating micro
components. Electrical discharge machining (EDM) is a promising machining method
for micro Machining. Electrical discharge machining (EDM) is a well-established
machining option for manufacturing geometrically complex or hard material parts
that are extremely difficult-to-machine by conventional machining processes. EDM
process is carried out by a series of electric discharges between the tool electrode and
the workpiece electrode, which are separated by a dielectric fluid with a gap-width of
several submicron to several hundred microns. The workpiece material is removed
through melting and evaporation due to the heat generated by electric discharges.
Even very hard materials which are difficult to machine with traditional techniques
could be machined by EDM, as long as they are electrically conductive. EDM is a
thermal process where material is removed by a succession of electrical discharges
occurring between an electrode and a work piece plunged in a dielectric fluid. Every
discharge ionizes a localized plasma canal. where temperature can become very high
(up to 10000 0C), leading to fusion and ebullition of metal of both facing materials.
Due to a very rapid heat exchange with the surrounding dielectric fluid, a part of the
melted metal is ejected out of the work piece creating small solid particles.
2. ULTRASONIC VIBRATION
Introducing vibrations to the EDM process has been widely studied since Kremer
proved that an ultrasonic(US) vibration of the electrode could greatly improve the
removal rate. Murthy demonstrated that assisting the EDM process with US
vibrations significantly reduced in active pulses in a steel work piece. Abdullah
concluded that employing US vibration in the electrode increased the MRR when
machining cemented tungsten carbide(WC-Co), and observed that arcing was reduced
and the stability of the process was improved. Srivastava combined US vibration and
EDM with cryogenically cooled electrode(CEDM) and noticed that the
implementation of US vibration helped improving the MRR and maintaining the
TWR and surface roughness(SR). Iwai tested three types of ultrasonic vibration
modes and achieved an improvement of the MRR when machining polycrystalline
composite diamond(PCD). Shervani-Tabar developed numerical studies to analyse
the effect of the gap and the dynamic pressure on the small bubbles produced in the
dielectric fluid between the tool and the work piece in ultrasonic assisted EDM.
4.VIBRATION MODES
5. EXPERIMENTAL SETUP
5.1.EDM PROCESS
For this study, a NX3 EDM machine from ONA was used. The tests were performed
using a copper rod electrode with a diameter of 15mm. Each electrode was polished
with a Mecatech 334 polisher from Presi until obtaining mirror finish in the front
face, in order to improve the surface roughness in finishing EDM operations.
Quenched and tempered 1.2344 (X40CrMoSiV5-1) tool steel (50 HRc) samples were
used for the EDM machining tests. The surface to be machined was grinded before
the EDM machining, in order to assure the same surface roughness and the same
parallelism between the electrode and the work piece in the different tests.
The objective roughness value(Ra) in these tests was around 0.30 mm, which was the
best obtainable roughness value taking into account the work piece material and
machining conditions mentioned in this section. The combination of the tool electrode
material, work piece material and machined area prevented from achieving 0.10 mm
surface roughness, which is the best roughness value that the cited NX3 EDM
machine can obtain.
The physical properties of the work piece material are shown in Table
1.
A special machining programme was prepared for these tests. This particular
programme starts with a high intensity regime, and it is progressively lowered until
finishing with the lowest intensity regime that the EDM machine can provide.
The US transducer used for this study was manufactured in Ti6Al4V with two PTZ-8
piezo- electric rings to generate the axial vibration. A MPI WG400 generator was
used for producing the electric field in the piezo electric rings, and it is able to supply
a power of 400W in 220V in a range of frequencies between 18 and 65 kHz. After
clamping the electrode in the US transducer and immersing both in the dielectric
liquid, the frequency of the US vibration was lowered from 40 kHz to 39.4 kHz. The
generator and the US transducer were synchronized at that frequency so as to make
the transducer vibrate in its second axial mode, producing the highest vibration
amplitude in the tool tip. The movements of the electrode and the changes in the most
important parameters of the EDM process were monitored during machining. After
concluding all the tests, these recorded signals were examined with a mathematical
analysis software in order to detect any unusual behaviour during the EDM process.
Fig. 2. Machined area with a circular ring due to the inhomogeneity in the debris
layer.
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PULSED ULTRASONIC ASSISTED EDM FOR FINISHING OPERATIONS
A visual observation of the machined area showed that the brightness was not
perfectly homogeneous, it being significantly brighter on the central region as
compared with the border. These brightness differences were caused by the variances
on roughness within the machined region. As it will be explained afterwards, this
phenomenon is caused by a dirt or debris layer which is retained in an in
homogeneous way between the tool electrode and the work piece.
Fig. 3. SEM images of the (a)centre (b)border of the machined area with EDM
process
In order to confirm the roughness difference between the brighter and matter zones in
the machined area, images captured with a Scanning Electron Microscopy (SEM)
have been compared in the Fig. 3. In each area three different profiles were measured
(indifferent directions), in order to represent better, the roughness value of the area,
and an average value was calculated. The measurements in each position were
repeated 3 times.
Fig. 4. Topographies of the (a)centre (b)border of the machined area with EDM
process
Fig. 5. Topographies of the (a)centre (b)border of the machined area with UEDM
process.
Fig. 6. Topographies of the (a)centre (b)border of the machined area with PUEDM
process
These topographies were obtained by the confocal microscope mentioned before, and
were used to measure the roughness value in the different areas of each machining
process.
6. RESULTS
During this study three different finishing processes were tested: EDM, UEDM and
PUEDM. The measured values showed a similar trend for each different process, and
that is why an average value has been used to represent the roughness value of each
process. From the mentioned figures difference in the surface finish quality and in the
brightness was appreciated between the Centre of the machined area and the border of
the area. This in homogeneity is common in the surfaces machined by finishing EDM
operations. A cross can be observed in case of the square electrodes and an exterior
ring in case of circular electrodes.
Fig. 7. Ra Comparison of EDM, UEDM and PUEDM in the centre and the border of
the Machined area
The EDM process by continuous US vibration is not beneficial for the final surface
roughness. The achieved Ra value of the finishing EDM process in the Centre was
0.37mm, this value increased to 0.57 mm in the case of assisting it with continuous
US vibration. However, applying the US vibrations discontinuously(PUEDM)
provided a better surface roughness than the EDM process without US vibration. The
Ra value achieved by the Pulsed Ultrasonic EDM process was 0.32 mm. The Ra value
in EDM was 0.57 mm, which increased up to 1.12 mm by UEDM, while with
PUEDM the surface roughness was reduced to 0.46 mm.
It can be observed that the Ra difference between the centre and the border is
smaller in the case of PUEDM. Hence, it can be concluded that the PUEDM process,
besides offering lower surface roughness values, assures better homogeneity in the
whole machined area. The key of the success in these finishing operations is not to
completely clean the gap between the tool electrode and work piece so that this dirt or
debris layer is trapped in the gap in each discharge. In this way, the finishing EDM
operations are very close to the so called Powder-Mixed Dielectric (PMD) EDM
process.
Fig. 8. Pictures of the machined area with (a) EDM process, (b)UEDM process and
(c) PUEDM process.
The mentioned dirt or debris layer of the finishing operations is not homogeneously
distributed. This is the main reason why the machined areas show the inhomogeneity
in the roughness and in the brightness, as it has been stated before. Maradia achieved
to improve the distribution of the dirt layer with a novel stochastic orbiting strategy.
They worked with an extremely low stray capacitance sinking EDM machine, and
combining it with the novel orbiting strategy, they obtained super-finishing surfaces
with a better distributed surface roughness.
Ultrasounds are generated by high frequency harmonic oscillations. As
they propagate through a physic medium (oil in this case) they are reflected on any
solid surface generating standing waves. Solid particles or debris tend to travel from
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PULSED ULTRASONIC ASSISTED EDM FOR FINISHING OPERATIONS
standing waves antinodes to nodes. Due to the fact that ultrasounds are applied by
pulses, the nodal distribution is constantly altered and therefore, particles migrate
randomly from one place to another. This fact explains that the pulsed ultrasonic
vibration causes a stochastic movement of the particles in the debris layer.
Consequently, the debris layer is distributed in a more homogeneous way, and the
surface roughness and brightness becomes more homogenous. In the case of UEDM,
as the US vibrations are active every moment, too many vibration and perturbation is
transmitted to the dielectric liquid, ejecting the debris particles out of the gap, which
is completely cleaned. Paradoxically, this fact is damaging for the surface finish. In
contrast, in the PUEDM process, as the US vibrations are activated and deactivated
periodically, the vibration generates enough movement to homogeneously disperse
the debris in the gap, but still not enough to eject the debris out of the gap.
7. CONCLUSION
The US vibration can achieve a more homogeneous distribution of the debris
layer in the whole machined area. This results in a more homogeneous surface
roughness and brightness. The Pulsed EDM process was proven to be the best process
for finishing operations among the tested processes. The surface roughness achieved
without US vibration was improved introducing pulsed US vibration in the finishing
EDM process. The Ra value was lowered in 14% in the centre of the machined area
and in 20% in the border. The equilibrium of the debris layer in the gap that is
obtained during the finishing EDM process was shown to be altered when the gap
was completely cleaned, which is the case of the UEDM process. This altered state
was demonstrated to be harmful for the final roughness. A process close to PMD-
EDM was induced by not completely cleaning the gap, assuring a better surface
roughness, since the discharge energy was better distributed and thus, shallower
craters were produced. Assisting the finishing EDM process with US vibrations can
be beneficial or detrimental, depending on the vibration and perturbation transmitted
to the dielectric liquid. In the case of applying US vibrations continuously, the
transmitted vibration was too high, the gap was cleaned, and thus, a higher surface
roughness value was obtained in the machined region. In contrast, applying the US
vibration in a pulsed mode, the vibrations transmitted maintained the debris in
suspension, but these vibrations were not high enough to eject the debris out of the
gap. In this way, a better discharge homogeneity was ensured with PUEDM process,
with a lower roughness value.
8.COMPARISON
EDM
Electrode material used are graphite, copper or brass.
PUEDM
Copper electrode is preferable for tool material in us assisted EDM.
9.APPLICATIONS
1. MICRO-SLIT MACHINING
PUEDM provides the aerospace industry with multi-process machine tools that
polishing, drill, route, clean, and inspect.
10.BIBLIOGRAPHY
Reference Journal:
STEAM TURBINE
Steam turbine implements the Rankine cycle
In this cycle there should be a pump, boiler, turbine and condenser
As there is only one steam turbine, which is capable of producing upto 120 MW
Steam enters the turbine with temperature 550oc and pressure 2200 pounds per sq.
inch
This steam rotates the turbine blades which are coupled to a generator
Producing additional electricity, about 120MW per HRSG unit
COMBINED CYCLE
The implementation of gas and steam turbine together i.e. Brayton and
Rankine cycle is known as the combined cycle
By combined cycle only it produces a total of about 350MW of electricity
Combined cycle increases the efficiency of the plant about 50% to 60%
Utilising maximum fuel energy and reducing the amount of waste heat to
atmosphere
The residual steam leaves the turbine at low pressure and low temperature,
about 100oc
This exhaust steam passes into condenser, which converts in to water
A cooling tower is used to cool the circulating water that passes through the
condenser
Cooling Tower
A cooling tower is a heat rejection device
It rejects waste heat to the atmosphere
There by cooling of water stream to a lower temperature.
DBT and WBT of air plays an important role in the working of a cooling
tower
As the WBT of air decreases, the capacity of cooling tower increases
The classification is based on the type of air induction into the tower
DEMINERALISATION PLANT
Source of water for the entire working of the plant is ACHANKOVIL river
Total water requirement is 1015m3/hr
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Water is drawn from Achankovil river from a single intake point (10 km away
from main plant area) into a desilting basin to remove sand and silt. Then
water is pumped from a raw water pump house to reservoir at plant site
through underground pipelines constructed by the state irrigation department.
Reservoir has 5 days of storage capacity
There is another makeup water pump at reservoir to pump water to clarifiers
in plant area for further processing.
After the clarification process, water is pumped to DM plant and to cooling
tower makeup sump.
Then the demineralized water is given to the boiler for production of steam.
Water to the township is supplied after filtering the water from DM plant
As the water that is fed into the plant is from the river, it contains lots of impurities,
sand, dissolved salts, suspended wastes etc. and if this water is fed into the plant
without proper treatment, then it may cause Blocks in heat exchanger tubes and
piping system, scaling in boilers and heat exchangers, Fouling and affect the
efficiency of the plant.
FOULING
Fouling is the accumulation of unwanted materials on solid surface that
detriment the proper functioning.
Fouling due to accumulation of living organisms like algae, bacteria, diatoms
etc. is called biofouling.
Fouling by non-living substances is called Inorganic fouling.
Biofouling can cause Microbiologically Influenced Corrossion(MIC).
PREVENTION OF FOULING
Macrofouling can be avoided by Prefiltration
Microfouling can be prevented by extensive methods of water treatment
which includes microfiltration,using ion exchange resins.
DEMINERALISATION PLANT
A demineralisation plant produces mineral free water by operating on the
principles of ion exchange and degasification.
The impurity ions present in water are replaced with ions released by the
resin.
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PULSED ULTRASONIC ASSISTED EDM FOR FINISHING OPERATIONS
RESINS
Resins are generally porous and used in the form of spherical beads of
diameter 0.5 to 1mm
Cation exchange resins exchanges all cations in water with hydrogen ions.
Anion exchange resins exchanges all anions in water with hydroxide ions.
DEMINERALISATION PROCESS
Complete demineralisation is achieved using 2 resins.
Water is first passed through a bed of cation exchange resin in hydrogen ion
form.
In cation exchange resin unit, all cations of water are replaced up by hydrogen
ions in resin.
Now water is passed on to anion exchange unit.
In anion exchange unit, all anions in water is replaced by hydroxide ions in
resin.
The released hydroxide ions react with hydrogen ions to form water.
REGENERATION OF RESINS
Resins are regenerated periodically in an interval of 12 to 48 hours.
Fires in electrical power generating plants can have costly and even fatal
consequences.
Fire protection s/m are a combination of mechanical and electrical
components.
These system needs regular attentions.
1.HYDRANT SYSTEM
Cover the entire power station.
This system involves a combination of valves, hoses, nozzles, pipes, water
storage tanks and hydrant valves.
SPRINKLER SYSTEM
Provide early fire control or extinguishment.
Consist of water supply system, providing adequate water pressure and flow
FOAM SYSTEM
Foam is used for the suppression of fire and can extinguish flammable liquid
or combustible liquid fires in four different ways:
Separate the flames from the fuel surface
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PORTABLE EXTINGUISHER
Used in NTPC is Carbon Dioxide fire extinguisher.
These contains pressurised liquid carbondioxide gas, which turns to gas when
expelled.
Effective on class B fires.
IN CASE OF FIRE.
If a fire occurs then the passage of information is like this
SAFETY MEASURES
Personal protective equipment.
Provide first-aid &prompt treatment of injuries & illness at work.
Publish regulations, instructions in the common language of employees.
Regular safety inspection.
Signs on floors are marked.
Unauthorised persons are not allowed to access the work sites.
Visitors are provided with protective equipment & guide.
Warning signs are displayed everywhere.