Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 2: Surface Integrity and Roundness

2002 ◽  
Vol 124 (3) ◽  
pp. 708-714 ◽  
Author(s):  
Jun Qu ◽  
Albert J. Shih ◽  
Ronald O. Scattergood
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Material Removal ◽  
Average Surface Roughness ◽  
Wire Edm ◽  
Average Surface ◽  
Arithmetic Average ◽  
Edm Process ◽  
Wire Feed ◽  
Cylindrical Wire

This study investigates the surface integrity and roundness of parts created by the cylindrical wire EDM process. A mathematical model for the arithmetic average surface roughness on the ideal surface of a cylindrical wire EDM workpiece is first derived. Effects of wire feed rate and part rotational speed on the surface finish and roundness for brass and carbide work-materials at high material removal rates are investigated. The pulse on-time and wire feed rate are varied to explore the best possible surface finish and roundness achievable by the cylindrical wire EDM process. This study has demonstrated that, for carbide parts, an arithmetic average surface roughness and roundness as low as 0.68 and 1.7 μm, respectively, can be achieved. Surfaces of the cylindrical EDM parts were examined using Scanning Electron Microscopy (SEM) to identify the macro-ridges and craters on the surface. Cross-sections of the EDM parts are examined using the SEM to quantify the sub-surface recast layers and heat-affected zones under various process parameters. This study has demonstrated that the cylindrical wire EDM process parameters can be adjusted to achieve either high material removal rate or good surface integrity and roundness.

Shaping Silicon Nitride With a Carbon Dioxide Laser by Overlapping Multiple Grooves

1989 ◽  
Vol 111 (4) ◽  
pp. 315-321 ◽  
Author(s):  
R. J. Wallace ◽  
S. M. Copley
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Economic Evaluation ◽  
Silicon Nitride ◽  
Material Removal ◽  
Carbon Dioxide Laser ◽  
Removal Rate ◽  
Average Surface Roughness ◽  
Average Surface ◽  
Arithmetic Average

In this research, the feasibility of shaping Si3N4 by overlapping multiple grooves produced with a continuously operated CO2 laser beam is demonstrated. The relationships of process parameters such as material removal rate and arithmetic average surface roughness to machine parameters such as feed and speed have been investigated. Strategies for laser shaping are discussed and an economic evaluation of laser shaping is presented.

Ultraprecision Machining of Si3N4 Ceramics with Shear-Thickening Polishing

2016 ◽  
Vol 1136 ◽  
pp. 490-493 ◽  
Author(s):  
Min Li ◽  
Bing Hai Lyu ◽  
Ju Long Yuan ◽  
Ping Zhao
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Shear Thickening ◽  
Average Surface Roughness ◽  
Ultraprecision Machining ◽  
Power Law Fluid ◽  
Average Surface ◽  
Fluid Characteristics

Shear-thickening polishing (STP) technology was used on ultraprecision machining of Si3N4 ceramics. The STP slurry with diamond abrasives was prepared for STP process and its rheological property was studied. The polishing performance of Si3N4 ceramics with STP was analyzed. Results show that STP slurry with diamond abrasives exhibits non-Newtonian power-law fluid characteristics with shear-thickening effect. As using STP slurry with abrasive particle size of 0.2 μm, the material removal rate changed from 4.22 to 4.05 μm/h after 60 mins ́ polishing; and decreased from 3.88 to 3.75 μm/h after 120 mins ́ polishing. The average surface roughness reduced from Ra 107.2 to Ra 6.5 nm after 120 mins ́ polishing.

Searching for a Pareto Optimal Solution Set of EDM Responses Applying Multi-Objective Simulated Annealing on RSM Model

2012 ◽  
Vol 622-623 ◽  
pp. 51-55
Author(s):  
Ushasta Aich ◽  
Amit Kumar Pal ◽  
Dipak Laha ◽  
Simul Banerjee
Keyword(s):  
Surface Roughness ◽  
Simulated Annealing ◽  
Material Removal ◽  
Removal Rate ◽  
Optimal Solution ◽  
Pareto Optimal Solution ◽  
Pareto Optimal ◽  
Average Surface Roughness ◽  
Average Surface ◽  
Optimal Solution Set

Simultaneous optimization of conflicting type responses like material removal rate (MRR) and average surface roughness (Ra) in stochastic type electrical discharge machining (EDM) process is a matter of concern to the process engineers. In this paper, EDM is first modeled by response surface methodology (RSM). Current setting, pulse on time and pulse off time were taken as the input parameters while material removal rate and average surface roughness as the responses. Multi-objective simulated annealing (MOSA) is then applied on these models. Pareto optimal solution set is thus developed. It would assist a process engineer to take decision regarding the optimal setting of the process parameters for a specific need-based requirement.

Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 1: Concept, Design, and Material Removal Rate

2002 ◽  
Vol 124 (3) ◽  
pp. 702-707 ◽  
Author(s):  
Jun Qu ◽  
Albert J. Shih ◽  
Ronald O. Scattergood
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Free Form ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Edm Process ◽  
Cylindrical Wire

Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of a precise, flexible, and corrosion-resistant underwater rotary spindle is first introduced. A detailed spindle error analysis identifies the major sources of error at different frequency spectrum. The spindle has been added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometries. The mathematical model for material removal rate of the free-form cylindrical wire EDM process is derived. Experiments were conducted to explore the maximum material removal rate for cylindrical and 2D wire EDM of carbide and brass work-materials. Compared to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates may be achieved in the cylindrical wire EDM, possibly due to better debris flushing condition.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

scholarly journals Ultrasonic dispersion method used in glass polishing experiment

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110118
Author(s):  
Zenan Chu ◽  
Tao Wang ◽  
Qiang He ◽  
Kai Zhao
Keyword(s):  
Surface Roughness ◽  
Rare Earth ◽  
Surface Morphology ◽  
Ultrasonic Method ◽  
Average Surface Roughness ◽  
Polishing Process ◽  
Ultrasonic Dispersion ◽  
Processing Efficiency ◽  
Average Surface ◽  
Evaluation Indexes

To solve the problems of low processing efficiency and poor glass surface quality when using rare earth polishing powder to grind super-hard K9 glass. The potential, phase structure, surface morphology, and particle size distribution of the nano-rare earth polishing powder were characterized. Compare the evaluation indexes such as polishing efficiency, surface morphology, and contact angle after the polishing process is changed. The results of the comparative study show that the average surface roughness of the glass after heating ultrasonic polishing process is 0.9064 nm, the polishing rate reaches 0.748 μm/min, the average surface roughness of the glass without heating ultrasonic polishing process is 1.3175 nm, and the polishing rate reaches 0.586 μm/min, the ultrasonic assisted polishing process is superior to the conventional polishing process. The heating ultrasonic method provides experimental basis for precise and rapid processing.

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