A method for reducing exit-hole completion time and side-sparking during electric discharge machining drilling (EDM-drill) process

Abstract

The present disclosure envisages a method (100) for reducing exit-hole completion time and side-sparking during Electric Discharge Machining (EDM) drilling process. The method (200) includes positioning (102) an electrode in proximity to a workpiece within a dielectric space. Further, the method (200) includes applying (104) a predefined peak-to-peak voltage between the electrode and the workpiece for the EDM drilling process. Furthermore, the method (200) includes modifying (106) the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process. The modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

Description

A METHOD FOR REDUCING EXIT-HOLE COMPLETION TIME AND SIDESPARKING DURING ELECTRIC DISCHARGE MACHINING DRILLING (EDM- DRILL) PROCESSFIELD

[0001] The present disclosure relates to Electric Discharge Machining (EDM). More particularly, embodiments of the present disclosure relate to a method for reducing exit-hole completion time and side-sparking during Electric Discharge Machining Drilling (EDM- Drill) process. Further, the method reduces exit-hole completion time by limiting undesirable side-sparking and electrode retraction events at the final, or “exit,” stage of the drilling process.DEFINITION

[0002] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used to indicate otherwise.

[0003] “Workpiece” refers to conductive material to be machined.

[0004] “Dielectric Space” refers to a non-conductive fluid (e.g., deionized water or oil) filling the gap between electrode and workpiece, enabling controlled spark discharge.

[0005] “Predefined Peak-to-Peak Voltage” refers to the initial, established voltage level applied between the electrode and the workpiece to initiate and sustain the EDM drilling process, facilitating efficient material removal in the early stages of drilling.

[0006] ‘Reduced Peak-to-Peak Voltage” refers to a controlled lower voltage applied at the exit stage, typically 40-50% of the initial drilling voltage, to mitigate side-sparking and arc formation.

[0007] “Exit Stage” refers to he final drilling phase as the electrode tip nears the opposite surface of the workpiece and dielectric fluid begins to escape, allowing gas infiltration.

[0008] “Side-Sparking” refers to unintended spark discharges occurring along the electrode’s periphery due to gas-filled voids that lower the breakdown threshold over larger gaps.

[0009] “Uninterrupted Spark Discharge” refers to the continuous flow of sparks required for efficient EDM drilling, which is maintained by reducing gas-filled area discharges to prevent arc conditions that would otherwise interrupt the drilling process.BACKGROUND

[0010] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0011]

[0012] Electric Discharge Machining (EDM) drilling is a precision machining method employed to remove material from a conductive workpiece. This is achieved by generating controlled electrical discharges, or sparks, between a tool electrode and the workpiece. A dielectric medium, typically a liquid such as deionized water or oil, fills the gap between the electrode and the workpiece to facilitate the discharge process. Material removal predominantly occurs at the front face of the electrode, where the gap is sufficiently narrow to allow the applied voltage to exceed the breakdown threshold of the dielectric medium, thereby initiating spark discharges that erode the workpiece.

[0013] During most of the drilling process, the dielectric medium remains in liquid form within the gap between the electrode tip and the workpiece. This liquid dielectric ensures that sparks are confined to the minimal frontal gap, facilitating precise material removal. The Larger side gaps surrounding the electrode are too wide for liquid dielectric breakdown, which effectively prevents unwanted lateral erosion and helps maintain a well-defined, slightly oversized hole profile.

[0014] As the drilling process nears the far surface of the workpiece commonly referred to as the “exit” or “breakout” stage the liquid dielectric begins to escape through the newly formed hole. The loss of liquid dielectric and infiltration of gas drastically alters electric discharge conditions. Gas is more readily ionized over larger distances compared to a liquid dielectric. Thus, as the electrode breaks through and the cavity is partially filled with gas pockets, sparks can initiate at the side regions of the electrode, where the gap previously insufficient for liquid breakdown now meets or exceeds the threshold for gas breakdown.

[0015] This phenomenon of unintended side-sparking in gas-filled regions leads to rapid debris accumulation and increases the probability of arcs forming. Arcing disrupts the machining process, often forcing the servo control system to retract the electrode repeatedly. This prolongs the completion time, accelerates electrode wear (e.g., bullet-nosing), and degrades the dimensional accuracy of the exit hole.

[0016] Conventional approaches, such as altering dielectric flushing rates or modifying feed control mechanisms, are generally insufficient to counteract the effects of dielectric loss and gas infiltration. Therefore, there is a critical need for a method to address side-sparkingcaused by gas pockets at the exit stage of EDM drilling. Thereby minimizing arc formation, reducing electrode retraction events, and optimizing completion time, material damage, and machining precision.

[0017] There is, therefore felt a need for a method for reducing exit-hole completion time and side-sparking during the Electric Discharge Machining Drill (EDM-Drill) process.OBJECTS

[0018] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:An object of the present disclosure is to provide a method for reducing exit-hole completion time and side-sparking during Electric Discharge Machining Drilling (EDM-Drill) process.

[0019] Another object of the present disclosure is to provide a method for reducing spark discharges in Gas in partially filled liquid dielectric spaces in the Electric Discharge Machining Drill (EDM-Drill) process.

[0020] Another object of the present disclosure is to provide a method that prevents undesirable side-sparking due to gas pockets at the exit stage by adjusting the spark discharge conditions.

[0021] Another object of the present disclosure is to provide a method that avoids electrode damage and maintains hole dimensional accuracy by preventing arcs and unnecessary servo retractions.

[0022] Another object of the present disclosure is to provide a method that can be integrated easily into existing EDM systems, either through manual adjustments or automated control mechanisms.

[0023] Another object of the present disclosure is to provide a method that reduces electrode retraction to a great extent.

[0024] Another object of the present disclosure is to provide a method that allows for unhindered Spark Discharge in Liquid Dielectric at the exit-hole, even in the presence of a very low quantity of liquid dielectric, allowing the electrode to travel further forward, completing the process quicker than before.

[0025] Another object of the present disclosure is to provide a method that is particularly useful when the workpiece is not fully submerged in a liquid dielectric.

[0026] Another object of the present disclosure is to provide a method that is easy to implement and can be performed manually or it can be Automated.

[0027] Another object of the present disclosure is to provide a method for mitigating and reducing the detrimental impact of electrode wear experienced during Electric Discharge Machining (EDM).

[0028] Yet, another object of the present disclosure is to provide a method to ensure exit hole diameters consistently meet tolerance levels, maintaining precision in the machining process.

[0029] Still, another object of the present disclosure is to provide a method to optimize the spark discharge, especially in scenarios involving partially fdled liquid dielectric spaces, improving the efficiency of EDM operations."

[0030] Yet, another object of the present disclosure is to develop a method that effectively minimizes spark discharge in gas filled spaces, thereby preserving electrode integrity and reducing completion time in EDM processes.

[0031] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.SUMMARY

[0032] This summary is provided to introduce concepts related to a method for reducing exit-hole completion time and side-sparking during Electric Discharge Machining (EDM) drilling process. The concepts are further described below in the following detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.

[0033] The present disclosure envisages a method for reducing exit-hole completion time and side-sparking during Electric Discharge Machining (EDM) drilling process. The method includes positioning an electrode in proximity to a workpiece within a dielectric space. Further, the method includes applying a predefined peak-to-peak voltage between the electrode and the workpiece for the EDM drilling process. Furthermore, the method includes modifying the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process. The modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

[0034] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage by a processor controlling a variable power source, and the processorbeing programmed to adjust the peak-to-peak voltage to less than half of the predefined peak- to-peak value at the exit stage.

[0035] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage manually by an operator or automatically through a controller-operated mechanism selected from a group comprising auto-transformers, electronic taps, and servocontrolled variable voltage sources.

[0036] In an embodiment, the controller-operated mechanism, comprising one of: a. a dimmerstat for voltage modification; b. a servo-controlled Auto-Transformer for voltage adjustment; c. an electronic selection of taps on a transformer; or d. a variable AC or DC power supply controlled electronically or manually.

[0037] In an embodiment, the modified voltage reduces the spark discharges specifically in gas-filled areas of the dielectric space at the exit stage, preventing an irreversible arc condition that would otherwise damage the electrode.

[0038] In an embodiment, the reduced peak-to-peak voltage minimizes electrode wear by decreasing occurrences of bullet-nose deformation at the electrode tip during the exit stage.

[0039] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage dynamically based on detected levels of engagement between the electrode and workpiece, allowing further voltage reduction if the electrode exit surface is detected.

[0040] In an embodiment, the method further comprises a step of applying a controlled pulse signal to disrupt arc initiation during the voltage reduction, ensuring continued operation without interruptions due to arc conditions.

[0041] In an embodiment, the modifying includes the step of reducing spark discharges in gas fdled spaces for EDM-Drilling in a partially fdled liquid dielectric space is achieved by the modified peak-to-peak voltage, allowing the electrode to continue forward travel even with a low quantity of liquid dielectric, thereby minimizing electrode retraction and expediting the completion of the drilling process.

[0042] In an embodiment, the modifying includes the step of real-time adjustment of the working voltage based on detection of gas filled spaces within the dielectric space, ensuring uninterrupted spark discharge.

[0043] In an embodiment, the method further comprises modifying the working voltage automatically based on real-time detection of gas-fdled spaces in the dielectric medium, to maintain uninterrupted spark discharge in liquid dielectric.

[0044] In an embodiment, the modifying includes the step of reducing the applied peak- to-peak voltage using a variable AC or DC power supply, controllable either manually or electronically.

[0045] In an embodiment, the method is particularly effective when the workpiece is not fully submerged in the liquid dielectric, allowing the electrode to travel further forward without being hindered by low liquid dielectric levels.

[0046] In an embodiment, the method includes the step of reducing the peak-to-peak voltage applied between the electrode and the workpiece during the exit stage of EDM drilling, thereby decreasing the minimum gap required for spark initiation and maintaining spark discharge within the small front gap containing liquid dielectric.

[0047] In an embodiment, the method includes the step of modulating the working voltage to suppress spark discharges in gas-fdled cavities, ensuring that sparking does not occur along the electrode’s sides, even in the presence of gas pockets.

[0048] In an embodiment, the method further comprises dynamically adjusting the applied voltage in real time to stabilize the spark discharge within the front gap, preventing side-sparking in gas-fdled spaces and avoiding electrode retraction.

[0049] In an embodiment, the reduction in peak-to-peak voltage is implemented using a variable voltage supply, which may be controlled manually or through an automated feedback system, based on real-time detection of dielectric conditions. In an embodiment, the method effectively prevents arcs and maintains electrode progression when gas pockets form in partially fdled liquid dielectric spaces, enabling faster and more precise completion of the drilling process, reducing completion times by 20-30%, and improving electrode longevity and maintain tighter dimensional tolerances on the exit hole.

[0050] The present disclosure further envisages a system for performing Electric Discharge Machining (EDM) drilling to reduce exit-hole completion time and side -sparking. The system comprises a memory, and a microprocessor. The memory stores a set of instructions for controlling a peak-to-peak voltage supply to an electrode. The microprocessor is configured to execute the instructions to: apply a predefined peak-to-peak voltage between the electrode and a workpiece for the EDM drilling process; and- modify the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process, the modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

[0051] In an embodiment, the microprocessor is further configured to detect exit conditions through signal feedback received from a feedback sensor and to initiate the reduced-voltage protocol in response to detected exit conditions.

[0052] In an embodiment, the system further comprises a control interface enabling manual or automated adjustment of voltage levels based on operator input or preprogrammed criteria stored in the memory.

[0053] In an embodiment, the microprocessor further comprises machine learning algorithms trained to optimize voltage adjustments based on previous exit times, machining conditions, and electrode wear data, thereby continuously refining the exit-hole completion time.

[0054] In an embodiment, the control interface allows an operator to set specific parameters for voltage modification, dielectric flushing rate, and electrode movement, where the processor executes these custom settings to achieve desired completion times and precision.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0055] A method for reducing exit-hole completion time and side-sparking during Electric Discharge Machining Drilling (EDM-Drill) process, of the present disclosure, will now be described with the help of the accompanying drawing, in which:

[0056] Figure 1 shows a method for reducing exit-hole completion time in the Electric Discharge Machining Drilling (EDM-Drill) process, in accordance with an embodiment of the present disclosure; and

[0057] Figure 2 shows a system for performing Electric Discharge Machining (EDM) drilling to reduce exit-hole completion time, in accordance with an embodiment of the present disclosure.LIST OF REFERENCE NUMERALSDETAILED DESCRIPTION

[0058] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

[0059] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0060] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units, and / or components, but do not forbid the presence or addition of one or more other features, elements, components, and / or groups thereof.

[0061] Electric Discharge Machines (EDM) are essential in precision machining, but the EDM encounters significant challenges during the Spark Discharge process when dealing with partially filled liquid dielectric spaces. These gas filled spaces create various technical issues that hinder efficient machining processes.

[0062] One of the primary issues faced in conventional EDM methods is electrode wear.As the EDM-Drill process continues, the electrode undergoes frontal wear, resulting in a phenomenon known as bullet nosing. This wear leads to exit hole diameters on the breakoutthat fall below the required tolerance levels, impacting the precision and quality of the machined workpiece.

[0063] Moreover, the spark erosion process thus has to be continued even after the breakout, to push the Electrode out beyond the tapered length, to achieve the machined dimensions of an entry / exit hole within tolerance.

[0064] Additionally, upon an exit or breakout the effective flushing of debris by the liquid dielectric is severely compromised and also results in a partially filled liquid dielectric space, which leads to a degradation of the process. These spaces pose a challenge to the machining process as they disrupt the functionality of the dielectric medium, affecting the overall efficiency and precision of the EDM operation.

[0065] A critical factor contributing to the degradation of the EDM process in these scenarios is the occurrence of Spark Discharge in Gas. This phenomenon (spark discharge in gas) leads to the deposition of carbon and metal debris on both the electrode and workpiece surfaces. As a consequence, an irreversible Arc condition develops, causing damage to the electrode. The Arc condition triggers the control servo to retract the electrode, resulting in an increase in completion time for the machining process.

[0066] The challenges within the realm of EDM have prompted the need for innovative solutions. These solutions aim to alleviate the issues associated with electrode wear, exit hole diameters below tolerance levels, compromised flushing, and the detrimental effects of Spark Discharge in Gas.

[0067] To this, the present disclosure proposes a method for reducing exit-hole completion time and side-sparking duringElectric Discharge Machining Drilling (EDM-Drill) process.

[0068] Referring to Figure 1, a method 100 for reducing exit-hole completion time and side-sparking during Electric Discharge Machining (EDM) drilling process is shown in accordance with an embodiment of the present disclosure. The order in which the method 100 is described is not intended to be construed as a limitation, and any number of the described method steps can be combined in any appropriate order to carry out the method 100 or an alternative method. Additionally, individual steps may be deleted from the method 100 without departing from the scope of the subject matter described herein. The method for reducing exit-hole completion time in Electric Discharge Machining (EDM), includes steps of:

[0069] At step 102: the method 100 includes positioning an electrode in proximity to a workpiece within a dielectric space.

[0070] At step 104: the method 100 includes applying a predefined peak-to-peak voltage between the electrode and the workpiece for the EDM drilling process.

[0071] At step 106: the method 100 includes modifying the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process. The modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

[0072] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage by a processor controlling a variable power source, and the processor being programmed to adjust the peak-to-peak voltage to less than half of the predefined peak- to-peak value at the exit stage.

[0073] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage manually by an operator or automatically through a controller-operated mechanism selected from a group comprising auto-transformers, electronic taps, and servocontrolled variable voltage sources.

[0074] In an embodiment, the modification of peak-to-peak voltage can be achieved through various means. It can be manually or by an automation device adjusted by a human operator, utilizing a dimmerstat for voltage modification. Alternatively, an automated approach involves a servo-controlled Auto-Transformer or electronic selection of taps of different voltages on a transformer. Furthermore, a variable AC or DC power supply, controllable electronically or manually, can be employed for this purpose.

[0075] In an embodiment, the modified voltage reduces the spark discharges specifically in gas-filled areas of the dielectric space at the exit stage, preventing an irreversible arc condition that would otherwise damage the electrode.

[0076] In an embodiment, the reduced peak-to-peak voltage minimizes electrode wear by decreasing occurrences of bullet-nose deformation at the electrode tip during the exit stage.

[0077] In an embodiment, the modifying includes the step of modifying the applied peak-to-peak voltage dynamically based on detected levels of engagement between the electrode and workpiece, allowing further voltage reduction if the electrode exit surface is detected.

[0078] In an embodiment, the method further comprises a step of applying a controlled pulse signal to disrupt arc initiation during the voltage reduction, ensuring continued operation without interruptions due to arc conditions.

[0079] In an embodiment, the modifying includes the step of reducing spark discharges in gas-filled spaces for EDM-Drilling in a partially filled liquid dielectric space is achievedby the modified peak-to-peak voltage, allowing the electrode to continue forward travel even with a low quantity of liquid dielectric, thereby minimizing electrode retraction and expediting the completion of the drilling process.

[0080] In an embodiment, the modifying includes the step of real-time adjustment of the working voltage based on the detection of gas-filled spaces within the dielectric space, ensuring uninterrupted spark discharge.

[0081] In an embodiment, the method further includes modifying the working voltage automatically based on real-time detection of gas-filled spaces in the dielectric medium, to maintain uninterrupted spark discharge in liquid dielectric.

[0082] In an embodiment, the modifying includes the step of reducing the applied peak- to-peak voltage using a variable AC or DC power supply, controllable either manually or electronically.

[0083] In an embodiment, the method 100 is particularly effective when the workpiece is not fully submerged in liquid dielectric, allowing the electrode to travel further forward without being hindered by low liquid dielectric levels.

[0084] In an embodiment, reducing spark discharges in gas further minimizes debris deposition on electrode and workpiece surfaces, preventing irreversible arc conditions.

[0085] In an embodiment, reducing exit-hole completion time involves avoiding spark discharge in gas within a partially filled liquid dielectric space.

[0086] In an embodiment, the modification of the peak-to-peak voltage enables unhindered spark discharge in a liquid dielectric at the exit hole, thereby facilitating quicker process completion even with a low quantity of liquid dielectric.

[0087] Referring to Figure 2, a system 200 for performing Electric Discharge Machining (EDM) drilling to reduce exit-hole completion time and side-sparking is shown in accordance with an embodiment of the present disclosure. The system 200 comprises a memory 202, and a microprocessor 204. The memory 202 stores a set of instructions for controlling a peak-to- peak voltage supply to an electrode. The microprocessor 204 is configured to execute the instructions to apply a predefined peak-to-peak voltage between the electrode and a workpiece for the EDM drilling process. Further, the microprocessor 204 modifies the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process. The modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

[0088] In an embodiment, the microprocessor 204 is further configured to detect exit conditions through signal feedback received from a feedback sensor 206 and to initiate the reduced-voltage protocol in response to detected exit conditions.

[0089] In an embodiment, the system 200 further includes a control interface 208 enabling manual or automated adjustment of voltage levels based on operator input or preprogrammed criteria stored in the memory 202.

[0090] In an embodiment, the microprocessor 204 further comprises machine learning algorithms trained to optimize voltage adjustments based on previous exit times, machining conditions, and electrode wear data, thereby continuously refining the exit-hole completion time.

[0091] In an embodiment, the control interface 208 allows an operator to set specific parameters for voltage modification, dielectric flushing rate, and electrode movement. The microprocessor 204 executes these custom settings to achieve desired completion times and precision.Working of the invention:

[0092] In standard EDM drilling, initial conditions are well controlled: The electrode advances while spark discharges occur at the front face, and flushing maintains a stable dielectric environment. As the electrode perforates the workpiece, dielectric fluid drains out, and gas pockets form, creating conditions favorable for spark initiation at larger gaps along the electrode’s sides.

[0093] Gas breaks down more readily than a liquid dielectric. While a liquid dielectric requires a very small gap for spark initiation, the presence of gas enables breakdown over a larger distance. The previously too-large side gap thus becomes suitable for gas sparks. Such side-sparking results in debris accumulation, higher arc probability, and frequent servo retractions.

[0094] By reducing the applied peak-to-peak voltage at this critical moment, the method constrains the conditions under which a spark can occur. The lowered voltage effectively increases the field strength needed at any given gap length. Consequently, the gas-filled gaps at the electrode sides are no longer at a suitable breakdown point, suppressing side-sparking and enabling stable conditions until the hole is fully completed.

[0095] The reduction in peak-to-peak voltage can be implemented either manually (e.g., via a dimmerstat or variable transformer) or automatically (e.g., servo-controlled transformers, electronic taps) triggered by feedback sensors that detect exit-stage conditions.Once implemented, the method reduces arcs, shortens cycle times, improves electrode longevity, and ensures more accurate hole geometries.EXAMPLE

[0096] Consider drilling a 5 mm-thick workpiece at an initial peak-to-peak voltage of 200 V. As the electrode nears the exit surface, dielectric fluid drains, creating gas pockets. Without intervention, side-sparking within these gas pockets leads to multiple arcs and servo retractions, prolonging the final drilling phase by approximately 25%.

[0097] By reducing the peak-to-peak voltage to approximately 90 V during this exit stage, the conditions for gas-induced side-sparking are suppressed. As a result, the electrode no longer experiences arcs and advances smoothly, completing the hole more rapidly and with improved dimensional fidelity.

[0098] The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, due to the nature of software, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.

[0099] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.TECHNICAL ADVANCEMENTS

[0100] The present disclosure described herein above has several technical advantages including, but not limited to, a method for reducing exit-hole completion time and sidesparking during Electric Discharge Machining Drilling (EDM-Drill) that:• reduces spark discharges in gas in a partially filled liquid dielectric space in Electric Discharge Machining (EDM);• reduces electrode retraction to a great extent;• allows for unhindered Spark Discharge in Liquid Dielectric at the exit-hole, even in the presence of a very low quantity of liquid dielectric, allowing the electrode to travel further forward, completing the process quicker than before;• is particularly useful when the workpiece is not fully submerged in liquid dielectric;• is easy to implement and can be performed manually or it can be Automated;• mitigates and redues the detrimental impact of electrode wear experienced during Electric Discharge Machining (EDM);• ensures exit hole diameters consistently meet tolerance levels, maintaining precision in the machining process;• reduces debris deposition on work surfaces, especially in scenarios involving partially filled liquid dielectric spaces, improving the efficiency of EDM operations;• effectively minimizes the adverse effects of spark discharge in gas, thereby preserving electrode integrity and reducing completion time in EDM processes;• reduces cycle time, or the time taken to complete a hole;• reduces damage to the electrode;• has entry and exit hole dimensions remain within tolerance; and• is very useful when workpieces are not fully submerged.

[0101] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0102] The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while theembodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0103] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

[0104] Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[0105] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher / lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

[0106] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A method (100) for reducing exit-hole completion time and side-sparking during Electric Discharge Machining (EDM) drilling process, comprising:• positioning (102) an electrode in proximity to a workpiece within a dielectric space;• applying (104) a predefined peak-to-peak voltage between the electrode and the workpiece for the EDM drilling process; and• modifying (106) the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process, wherein the modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

2. The method (100) as claimed in claim 1, wherein the modifying includes the step of modifying the applied peak-to-peak voltage by a processor controlling a variable power source, and the processor is programmed to adjust the peak-to-peak voltage to less than half of the predefined peak-to-peak value at the exit stage.

3. The method (100) as claimed in claim 1, wherein the modifying includes the step of modifying the applied peak-to-peak voltage manually by an operator or automatically through a controller-operated mechanism selected from a group comprising autotransformers, electronic taps, and servo-controlled variable voltage sources.

4. The method (100) as claimed in claim 3, wherein the controller-operated mechanism, comprising one of: a. a dimmerstat for voltage modification; b. a servo-controlled Auto-Transformer for voltage adjustment; c. an electronic selection of taps on a transformer; or d. a variable AC or DC power supply controlled electronically or manually.

5. The method (100) as claimed in claim 1, wherein the modified voltage reduces the spark discharges specifically in gas-filled areas of the dielectric space at the exit stage, preventing an irreversible arc condition that would otherwise damage the electrode.

6. The method (100) as claimed in claim 1, wherein the reduced peak-to-peak voltage minimizes electrode wear by decreasing occurrences of bullet-nose deformation at the electrode tip during the exit stage.

7. The method (100) as claimed in claim 1, wherein the modifying includes the step of modifying the applied peak-to-peak voltage dynamically based on detected levels of engagement between the electrode and workpiece, allowing further voltage reduction if the electrode exit surface is detected.

8. The method (100) as claimed in claim 1, which further comprises a step of applying a controlled pulse signal to disrupt arc initiation during the voltage reduction, ensuring continued operation without interruptions due to arc conditions.

9. The method (100) as claimed in claim 1, wherein the step of modifying includes the step of reducing spark discharges in gas-fdled spaces for EDM-Drilling in a partially filled liquid dielectric space is achieved by the modified peak-to-peak voltage, allowing the electrode to continue forward travel even with a low quantity of liquid dielectric, thereby minimizing electrode retraction and expediting the completion of the drilling process.

10. The method (100) as claimed in claim 1, wherein the modifying includes the step of real-time adjustment of the working voltage based on the detection of gas-filled spaces within the dielectric space, ensuring uninterrupted spark discharge.

11. The method (100) as claimed in claim 1, which further comprises modifying the working voltage automatically based on real-time detection of gas-filled spaces in the dielectric medium, to maintain uninterrupted spark discharge in a liquid dielectric.

12. The method (100) as claimed in claim 1, wherein the step of modifying includes the step of reducing the applied peak-to-peak voltage using a variable AC or DC power supply, controllable either manually or electronically.

13. The method (100) as claimed in claim 1, wherein the method (100) is particularly effective when the workpiece is not fully submerged in liquid dielectric, allowing the electrode to travel further forward without being hindered by low liquid dielectric levels.

14. A system (200) for performing Electric Discharge Machining (EDM) drilling to reduce exit-hole completion time and side-sparking, the system comprising• a memory (202) storing a set of instructions for controlling a peak-to-peak voltage supply to an electrode; and• a microprocessor (204) configured to execute the instructions to: apply a predefined peak-to-peak voltage between the electrode and a workpiece for the EDM drilling process; and- modify the applied peak-to-peak voltage to a reduced value during an exit stage of the EDM drilling process, wherein the modified voltage reduces spark discharge in gas within the dielectric space, facilitating electrode advancement without significant retraction and minimizing exit-hole completion time.

15. The system (200) as claimed in claim 14, wherein the microprocessor (204) is further configured to detect exit conditions through signal feedback received from a feedback sensor (206) and to initiate the reduced-voltage protocol in response to detected exit conditions16. The system (200) as claimed in claim 14, which further comprises a control interface (208) enabling manual or automated adjustment of voltage levels based on operator input or pre-programmed criteria stored in the memory (202).

17. The system (200) as claimed in claim 14, wherein the microprocessor (204) further comprises machine learning algorithms trained to optimize voltage adjustments based on previous exit times, machining conditions, and electrode wear data, thereby continuously refining the exit-hole completion time.

18. The system (200) as claimed in claim 16, wherein the control interface (208) allows an operator to set specific parameters for voltage modification, dielectric flushing rate, and electrode movement, where the microprocessor (204) executes these custom settings to achieve desired completion times and precision.

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