Experiment investigation of using wire electrochemical machining in deionized water to reduce the wire electrical discharge machining surface roughness

2019 ◽  
Vol 102 (1-4) ◽  
pp. 343-353 ◽  
Author(s):  
Xiaoyu Wu ◽  
Shujuan Li ◽  
Wen Zhao ◽  
Lin Tang ◽  
Zhipeng Li
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Deionized Water ◽  
Wire Electrical Discharge Machining ◽  
The Wire ◽  
Wire Electrochemical Machining

Analysis of wire erosion and workpiece surface roughness in wire electrical discharge machining

2003 ◽  
Vol 217 (5) ◽  
pp. 633-642 ◽  
Author(s):  
N Tosun ◽  
C Cogun
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Open Circuit ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Workpiece Surface ◽  
The Wire ◽  
Dielectric Flushing ◽  
Wire Wear

In this study, the effects of machining parameters on the wire wear, on the size of erosion craters on the wire and on the workpiece surface roughness were investigated experimentally in wire electrical discharge machining (WEDM). An attempt was made to correlate the crater volume and the pulse energy. The experiments were conducted under different settings of pulse duration, open-circuit voltage, wire speed and dielectric flushing pressure. The variations of the wire wear, the size of erosion craters on the wire and the workpiece surface roughness with machining parameters were modelled mathematically by using regression analysis. The relationship between the workpiece surface roughness and the crater size was established. The analysis of variance (ANOVA) and F-test were performed to obtain statistically significant process parameters and the percentage contribution of these parameters to the performance outputs.

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

2021 ◽  
pp. 095440892110414
Author(s):  
TS Senthilkumar ◽  
R Muralikannan ◽  
T Ramkumar ◽  
S Senthil Kumar
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Box Behnken Design ◽  
Pulse On Time

A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

scholarly journals Influence of Energy Parameters of Micro WEDM on Kerf

2012 ◽  
Vol 576 ◽  
pp. 527-530
Author(s):  
Mohammad Yeakub Ali ◽  
W.Y.H. Liew ◽  
S.A. Gure ◽  
B. Asfana
Keyword(s):  
Experimental Data ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Wire Electrode ◽  
Wire Vibration ◽  
The Wire ◽  
Micro Wedm

This paper presents the estimation of kerf width in micro wire electrical discharge machining (micro WEDM) in terms of machining parameters of capacitance and gap voltage. An empirical model is developed by the analysis of variance (ANOVA) of experimental data. Using a wire electrode of 70 µm diameter, a minimum kerf width is found to be 92 µm for the micro WEDM parameters of 0.01 µF capacitance and 90.25 V gap voltage. Around 30% increament of the kerf is found to be high. The analysis also revealed that the capacitance is more influential parameter than gap voltage on kerf width produced by micro WEDM. As the gap voltage determines the breakdown distance and affects the wire vibration, the wire vibration factor is to be considered in the analysis and in formulation of model in future study.

Surface Roughness at Wire Electrical Discharge Machining

2015 ◽  
Vol 760 ◽  
pp. 551-556 ◽  
Author(s):  
Oana Dodun ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Vasile Merticaru ◽  
Gheorghe Nagîţ
Keyword(s):  
Surface Roughness ◽  
Empirical Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Wire Electrical Discharge Machining ◽  
Power Type ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining is a machining method by which parts having various contours could be detached from plate workpieces. The method uses the electrical discharges developed between the workpiece and the wire tool electrode found in an axial motion, when in the work zone a dielectric fluid is recirculated. In order to highlight the influence exerted by some input process factors on the surface roughness parameter Ra in case of a workpiece made of an alloyed steel, a factorial experiment with six independent variables at two variation levels was designed and materialized. As input factors, one used the workpiece thickness, pulse on time, pulse off-time, wire axial tensile force, current intensity average amplitude defined by setting button position and travelling wire electrode speed. By mathematical processing of the experimental results, empirical models were established. Om the base of a power type empirical model, graphical representations aiming to highlight the influence of some input factors on the surface roughness parameter Ra were achieved. The power type empirical model facilitated establishing of order of factors able to exert influence on the surface roughness parameter Ra at wire electrical discharge machining.

scholarly journals Experimental Research on Discharge Forming Cutting-Electrochemical Machining of Single-Crystal Silicon

2021 ◽  
Vol 2021 ◽  
pp. 1-13
Author(s):  
Bin Xin ◽  
Wei Liu
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Single Crystal Silicon ◽  
Recast Layer ◽  
Movement Speed ◽  
Crystal Silicon ◽  
Wedm Process

During the wire electrical discharge machining (WEDM) process, a large number of discharge pits and a recast layer are easily generated on the workpiece surface, resulting in high surface roughness. A discharge forming cutting-electrochemical machining method for fabricating single-crystal silicon is proposed in this study to solve this problem. On the same processing equipment, single-crystal silicon is first cut using the discharge forming cutting method. Second, electrochemical anodic reaction technology is used to dissolve the discharge pits and recast layer on the single-crystal silicon surface. The machining mechanism of this process, the surface elements of the processed single-crystal silicon and a comparison of the kerf width are analyzed through experiments. On this basis, the influence of the movement speed of the copper foil electrode during electrochemical anodic dissolution on the final surface roughness is qualitatively analyzed. The experimental results show that discharge forming cutting-electrochemical machining can effectively eliminate the electrical discharge pits and recast layer, which are caused by electric discharge cutting, on the surface of single-crystal silicon, thereby reducing the surface roughness of the workpiece.

scholarly journals Wire Electrical Discharge Machining—A Review

Machines ◽  
2020 ◽  
Vol 8 (4) ◽  
pp. 69
Author(s):  
Laurenţiu Slătineanu ◽  
Oana Dodun ◽  
Margareta Coteaţă ◽  
Gheorghe Nagîţ ◽  
Irina Beşliu Băncescu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrode ◽  
Machining Processes ◽  
Scientific Papers ◽  
The Wire ◽  
Machining Productivity ◽  
Machined Surfaces

Wire electrical discharge machining has appeared mainly in response to the need for detachment with sufficiently high accuracy of parts of plate-type workpieces. The improvements introduced later allowed the extension of this machining technology to obtain more complex ruled surfaces with increasingly high requirements regarding the quality of the machined surfaces and the productivity of the wire electrical discharge machining process. Therefore, it was normal for researchers to be interested in developing more and more in-depth investigations into the various aspects of wire electrical discharge machining. These studies focused first on improving the machining equipment, wire electrodes, and the devices used to position the clamping of a wire electrode and workpiece. A second objective pursued was determining the most suitable conditions for developing the machining process for certain proper situations. As output parameters, the machining productivity, the accuracy, and roughness of the machined surfaces, the wear of the wire electrode, and the changes generated in the surface layer obtained by machining were taken into account. There is a large number of scientific papers that have addressed issues related to wire electrical discharge machining. The authors aimed to reveal the aspects that characterize the process, phenomena, performances, and evolution trends specific to the wire electrical discharge machining processes, as they result from scientific works published mainly in the last two decades.

Effects of Machining Fluid on Electric Discharge Machining of SiC Ingot

2014 ◽  
Vol 778-780 ◽  
pp. 767-770 ◽  
Author(s):  
Norimasa Yamamoto ◽  
Satarou Yamaguchi ◽  
Tomohisa Kato
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Ion Exchange ◽  
Electric Discharge ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electric Discharge Machining ◽  
The Wire ◽  
Characteristic Features ◽  
First Time

Recently, ingots of silicon carbide have been adapted to be sliced by the wire-cut electrical discharge machining. Fast slicing, and the reduction in the loss are important for slicing of the wafer. In this paper, characteristic features of the electric discharge machining in the ion-exchange water and the fluorine-based fluid were compared for these improvement. The discharge was caused by a pulse voltage applied to a ingot of silicon carbide and the wire in machining fluid, and the slicing was proceeded. As a result, improvement of surface roughness and kerf loss was confirmed, for the first time. In addition, the improving methods for fast slicing were considered.

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