Dual synchronous suction-ejection portable dielectric flushing system and method for electro-discharge machining process

Abstract

The present invention relates to a dual synchronous suction-ejection portable dielectric flushing system (100) and method for EDM process. The system comprises of converging (106) and diverging (104) open end nozzles designed to be closely pointed at the machining zone such that the open ends (O1, O2) face towards each other. The nozzles (104, 106) are connected to a dielectric filter (101) and a flow pump (102) in such a way that it generates simultaneous pull-push effect on the debris particles generated during EDM operation as the dual synchronous suction-ejection dielectric flow action takes places at the machining region. The flushing system can be directly place within the dielectric filled work tank of the EDM setup in the aforementioned manner before the machining operation and the flow pump needs to be provided with a power supply to experience the dielectric flushing effect effectively. It will generate high pressure debris mixed dielectric suction and high velocity debris free dielectric ejection at the tool-workpiece interface. [figure 1]

Description

FIELD OF THE INVENTIONThis invention relates to a dual synchronous suction-ejection dielectric flushingsystem and method for electro-discharge machining process.BACKGROUND OF THE INVENTIONElectro-discharge machining is an electro-thermal advanced manufacturing processin which material removal occurs by melting and vaporisation at extremely hightemperature generated by the electric spark acting at the tool-workpiece interface.During EDM process, the tool and workpiece remain submerged in a dielectric fluidmedium filled inside a work tank. The sudden condensation of eroded molten andvaporised material from the tool-workpiece interface forms small debris particleswhich often gets flushed away from the machining zone during each pulse intervalby implementing a dielectric flushing system.In most cases, due to ineffective flushing effect of the flushing system the moltenand vaporised material rapidly condenses and remains attached to the machinedzone (or) it's surrounding leading to the recast layer formation and poor surfacequality. Some debris particles remain suspended in the dielectric near the machiningzone and assists in higher order discharges which reduces the machiningperformance. The aforementioned setbacks can be addressed by implementingadvanced dielectric flushing system which generates better flushing effect withenhanced debris evacuation approach from the machining zone.US20240165724A1 describes an integrated external flushing system for EDMprocess assembled with the electrode positioned in an electrode guide. The systemincludes a guide cap and a concentric flushing channel defined between the guidecap and the electrode guide so as to allow the flushing fluid to remain attached tothe electrode guide.WO2011006039A2 discloses a high velocity method of delivery of dielectricflushing fluid to the electrical discharge machine work zone. The high velocity isaccomplished by utilizing flushing flow past the single point electrode tip at leastabout 75 inches / second and dielectric water can be used as the flushing fluid.IN202211036538A describes a tool plate with pre-drilled micro-holes based suctionflushing system for reverse EDM process. It comprises of a tool plate specificallydesigned with micro-holes attached to a funnel sandwiched to the tool plate and thefixture for generating suction action to flow the debris filled dielectric to thedielectric reservoir.CN116275320A discloses a porous rotary electrode based EDM process for highspeedmachining. The synchronous rotation of multiple tool electrodes duringmachining generates inner flushing which is more uniform than the side flushingthat improves the machining speed and aspect ratio of machined hole.Shah et al. (2023) proposed a novel dielectric rotation strategy based flushingmechanism for EDM process. They implemented a magnetic stirrer apparatus wasutilized to attain the dielectric rotation by placing a magnetic stirrer bar at thebottom of the work tank. They observed improved normal pulse frequency thanbasic side flushing system.Zhang et al. (2015) developed an internal side flushing system for EDM and electrochemicalmachining process. The dielectric flow passage was built in both thesideways within the electrode guide to provide internal flushing effect during themachining operation. They observed improved surface quality of micro-holes andlowers the recast layer formation.Jiang et al. (2021) utilized porous electrode prepared using high-temperaturesintering for flushing in EDM process. The dielectric flows through the pores of theelectrode towards the machining zone for generating the debris flushing actionduring the machining operation.Wang et al. (2019) implemented high-speed gas internal flushing from within thetubular electrode and an external liquid high-speed side flushing for EDM millingprocess. They observed 23% higher machining rate and 30% lower surfaceroughness as compared to traditional flushing system in EDM process.During EDM, the debris flushing generated by single jet flushing mechanismproduces low flushing efficiency which leads to debris accumulation and thickrecast formation.How the invention solves the problemIn commercially available electro-discharge machine (EDM), it possesses amachining tank in which the workpiece and tool are initially fixed, then the tank isfilled with dielectric fluid for submerging the tool and workpiece interactingsurfaces. During the machining operation, a jet flushing system is provided at themachining zone in which the flushing nozzle is placed at near the tool-workpieceinterface. The used dielectric is continuously drained during the machiningoperation through a pipe outlet present at the peripheral corner of the work tankaway from the machining zone. The jet flushing mechanism generates lowefficiency flushing effect at the machining zone which leads to debris accumulationand thick recast formation. These phenomena causes' harmful and irregulardischarges such as arcing, short-circuiting, tool lift-time delay, higher orderdischarges, etc., during the EDM operation.The aforementioned issues lead to lower machining rate, poor machined surfacequality, power consumption losses and reduced productivity. Thus, the presentinvention describes a dual synchronous debris flushing system which works bygenerating simultaneous high-pressure suction and pressure flow of dielectric at themachining zone by placing two differently designed pipe nozzles for dielectricsuction and ejection action, to achieve improved debris flushing effect andenhanced process efficiency.High pressure dielectric suction and ejection mechanism based dielectric debrispressure flushing system with two differently shaped flushing nozzle heads near thetool-workpiece interface as proposed in the present invention solves the existingproblems.A dual dielectric suction-ejection effect generating flushing system which providessynchronous pull-push effect on the debris particles released at the machining zoneby placing two differently shaped nozzles connected to a flow pump specificallyfor high pressure debris mixed dielectric suction and high velocity fresh dielectricejection at the machining zone throughout the operation.OBJECTS OF THE INVENTIONIt is therefore an object of this invention to provide a dual synchronous suctionejectionportable dielectric flushing system in an electro discharge machining(EDM) setup.Another object of the invention is to provide a method of dual synchronous suctionejectionportable dielectric flushing with that system.Another object of this invention is to produce simultaneous pull-push effect actingon the debris particles produced in an electro discharge machining (EDM) setup.Another object of this invention is to generate high pressure debris mixed dielectricsuction and high velocity debris free dielectric ejection at the tool-workpieceinterface.These and other objects and advantages of the invention will be apparent from theensuing description when read in conjunction with the accompanying drawing.SUMMARY OF THE INVENTIONThe current invention describes a dual synchronous suction-ejection portabledielectric flushing system and method which comprises of a flow pump,dielectric filter, connecting flow pipe, converging and diverging nozzles.Initially, a dielectric filter inlet is connected to a flow pipe which has one openingend provided with an outward diverging nozzle. The dielectric filter outlet isconnected to a flow pipe, the other end of the flow pipe connects to the suctioninlet of the flow pump. The flow pump ejection outlet is further connected to aflow pipe having its one opening end provided with an outward convergingnozzle. For initiating the flushing effect, the dual synchronous dielectric flushingsystem can to be placed within a dielectric filled work tank of an EDM systemwhere the workpiece and tool have been placed rigidly with the aid of fixtures.The two diverging and converging nozzles attached to the respective flow pipesneeds to be placed near the machining zone with their open ends facing towardseach other.When the power supply is connected to the flow pump, the diverging inlet nozzlewill allow high pressure suction of debris mixed dielectric from the machiningzone during the EDM process which will lead to the suction flushing effect.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGFigure 1: The schematic diagram of the dual synchronous suction-ejectionportable dielectric flushing system (100) and its illustration for a possible way ofpositioning in a basic electro discharge machining (EDM) setup.DETAIL DESCRIPTION OF THE PRESENT INVENTION WITHREFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERREDEMBODIMENTSIn the following description, numerous specific details are set forth in order toprovide a thorough understanding of embodiments of the present disclosure. It willbe apparent to one skilled in the art that embodiments of the present disclosure maybe practiced without some of these specific details.Accordingly, those of ordinary skill in the art will recognize that various changesand modifications of the embodiments described herein can be made withoutdeparting from the scope of the invention.The terms and words used in the following description and claims are not limitedto the bibliographical meanings but are merely used to enable a clear and consistentunderstanding of the invention.As used in the description herein and throughout the claims that follow, the meaningof "a," "an," and "the" includes plural reference unless the context clearly dictatesotherwise. Also, as used in the description herein, the meaning of "in" includes "in"and "on" unless the context clearly dictates otherwise.The current invention describes a dual synchronous suction-ejection portabledielectric flushing system which comprises of a flow pump, dielectric filter,connecting flow pipe, converging and diverging nozzles.Fig. 1 depicts the schematic diagram of the dual synchronous suction-ejectionportable dielectric flushing system (100) and its illustration for a possible way ofpositioning in a basic electro discharge machining (EDM) setup.Referring to Fig.1, a dual synchronous suction-ejection portable dielectricflushing system (100) comprises of a flow pump (102), dielectric filter (101),connecting flow pipe (103 and 105), converging (106) and diverging (104)nozzles.Initially, a dielectric filter (101) inlet is connected to a flow pipe (103) which hasone opening end provided with an outward diverging nozzle (104). The dielectricfilter (101) outlet is connected to a flow pipe, the other end of the flow pipeconnects to the suction inlet of the flow pump (102). The flow pump ejectionoutlet is further connected to a flow pipe (105) having its one opening endprovided with an outward converging nozzle (106).Referring to Fig. 1, the dual synchronous suction-ejection portable dielectricflushing system can be placed inside an EDM setup work tank (107) which isfilled with dielectric fluid (108). Here, the tool (110) and workpiece (109) areplaced rigidly inside the work tank (107) and the nozzle openings of the flushingsystem (100) can be pointed closely towards the machining zone for the effectiveworking of the flushing system.Initially, the dielectric filter (101) inlet (In) is connected to a first opening of theflow pipe (103) which has the second opening end provided with an outwarddiverging nozzle (104). The dielectric filter (101) outlet (Ot) is connected to theflow pump (102). The flow pump (102) ejection outlet is further connected to thesecond flow pipe (105) having its one opening end provided with an outwardconverging nozzle (106).For initiating the flushing effect, the proposed dual synchronous dielectricflushing system (100) can be placed within a dielectric filled work tank (107) ofan EDM system where the workpiece (109) and the tool (110) have been placedrigidly with the aid of fixtures. The two diverging (104) and converging (106)nozzles attached to the respective flow pipes (103, 105) needs to be placed nearthe machining zone with their open ends (O1, O2) facing towards each other.When the power supply is connected to the flow pump (102), the diverging inletnozzle (104) will allow high pressure suction of debris mixed dielectric from themachining zone during the EDM process which will lead to the suction flushingeffect.Further, the debris mixed dielectric will flow towards the dielectric filter (101)which will produce fresh debris free dielectric to flow through its outlet (Ot)towards the flow pump (102) inlet. The flow pump (102) will eject the freshdebris free dielectric through its outlet which will reach the machining zone bythe converging outlet nozzle (106) generating high velocity ejection of freshdebris free dielectric which will lead to jet flushing effect. The simultaneous pullpusheffect acting on the debris particles produced during the EDM operation atthe machining zone due to the synchronous dielectric suction-ejection action willlead to the enhanced flushing effect.A method of dual synchronous suction-ejection portable dielectric flushing forproducing debris free dielectric during electro discharge machining (EDM), withthe proposed system (100) is as follows:A power supply is connected to the flow pump (102). It generates suction ofdebris mixed dielectric from a machining zone during the EDM process throughthe diverging inlet nozzle (104) connected to the dielectric filter (101) via thefirst flow pipe (103). A flow of the debris mixed dielectric is generated towardsthe dielectric filter (101) to produce fresh debris free dielectric and said freshdielectric is passed towards the flow pump (102) inlet through its outlet (Ot). Afresh debris free dielectric is ejected by the flow pump (102) towards theconverging outlet nozzle (106) via the second flow pipe (105). It leads to thefresh debris free dielectric flow with a jet flushing effect to the machining zoneof the EDM system with the simultaneous pull-push effect acting on the debrisparticles produced by the diverging (104) and the converging (106) nozzlesassociated with the dielectric filter (101) and the flow pump (102).The advantages and improvements over the existing methods, devices ormaterials in terms of efficiency, yield, cost etc.- Double flushing effect generated by dielectric suction-ejection simultaneously- Reduced debris deposition and recast formation- Enhanced discharge stability and consistency- Better machining performance and improved efficiency- Low cost and portable flushing system with easy operating capability usageIt should be apparent to those skilled in the art that many more modificationsbesides those already described are possible without departing from the inventiveconcepts herein.Moreover, in interpreting both the specification and the claims, all terms shouldbe interpreted in the broadest possible manner consistent with the context. Inparticular, the terms "comprises" and "comprising" should be interpreted asreferring to elements, components, or steps in a non- exclusive manner,indicating that the referenced elements, components, or steps may be present, orutilized, or combined with other elements, components, or steps that are notexpressly referenced.The present disclosure is not limited to the described embodiments, versions orexamples, which are included to enable a person having ordinary skill in the artto make and use the present disclosure when combined with information andknowledge available to the person having ordinary skill in the art and thus it isintended by the appended claims to cover all such modifications and adaptationswhich fall within the scope of the present subject matter.

Claims

1. A dual synchronous suction-ejection portable dielectric flushing system (100) placed within a dielectric filled work tank for producing debris free dielectric during electro discharge machining (EDM), characterised in that said system (100) comprises: a dielectric filled work tank (107) of an EDM system wherein a workpiece (109) and a tool (110) being placed with the aid of fixtures therewithin, a diverging (104) and a converging (106) nozzles attached to respective first and second flow pipes (103, 105) being placed at a machining zone of the EDM system with their open ends (O1, O2) facing towards each other, a dielectric filter (101) connected to the first flow pipe (103) at the opposing end (In) of the diverging nozzle (104), a flow pump (102) connected to an outlet (Ot) of the dielectric filter (101) at one end and to the converging nozzle (106) through the second flow pipe (105) on the other end, wherein upon a power supply being connected to the flow pump (102), the diverging inlet nozzle (104) being configured to generate high pressure suction of debris mixed dielectric from the machining zone during the EDM process and to pass said debris to the dielectric filter (101) for filtering, wherein the flow pump (102) connected to the outlet (Ot) of the dielectric filter (101) being configured to eject fresh debris free dielectric through its outlet to reach the machining zone by the converging outlet nozzle (106) generating high velocity ejection of fresh debris free dielectric leading to jet flushing effect.

2. A method of dual synchronous suction-ejection portable dielectric flushing for producing debris free dielectric during electro discharge machining (EDM), characterised in that said method comprises the steps of: connecting a power supply to a flow pump (102) in the system (100), generating suction of debris mixed dielectric from a machining zone during the EDM process through a diverging inlet nozzle (104) connected to a dielectric filter (101) via a first flow pipe (103), generating flow of the debris mixed dielectric towards the dielectric filter (101) to produce fresh debris free dielectric and to pass said fresh dielectric towards a flow pump (102) inlet through its outlet (Ot), ejecting fresh debris free dielectric by the flow pump (102) towards a converging outlet nozzle (106) via a second flow pipe (105), leading the fresh debris free dielectric with a jet flushing effect to the machining zone of the EDM system with the simultaneous pull-push effect acting on the debris particles produced by the diverging (104) and the converging (106) nozzles associated with the dielectric filter (101) and the flow pump (102).

3. The method as claimed in claim 2, wherein the suction-ejection action being performed in a synchronous manner.