Analysis and Design of Wire Transport System in Microwire-Electronic Discharge Machining

2013 ◽  
Vol 1 (2) ◽  
Author(s):  
P. W. Wang ◽  
C. S. Yang
Keyword(s):  
Surface Roughness ◽  
Transport System ◽  
High Frequency ◽  
Vibration Absorber ◽  
Wire Tension ◽  
Analysis And Design ◽  
Corner Cutting ◽  
The Wire ◽  
Corner Error ◽  
Wire Feed

A dynamic model for analyzing the wire transport system of micro w-EDM (wire electronic discharge machining) is proposed. Based on the model, two mechanisms are proposed to stabilize the wire tension. The first mechanism is the active wire feed apparatus where the wire spool is fed by a motor actively, instead of passively pulled by the windup motor. Hence, the inertia loading of the wire spool can be isolated from the system. The second mechanism is mounting a multilayer damped vibration absorber (MDVA) on the system. As the wire tension variation occurs, the MDVA oscillates to attenuate the wire tension variation. The performances of both mechanisms on the wire tension variation are theoretically investigated and experimentally validated through corner cutting on the 1.0 mm thickness tungsten carbide. Results show that the wire tension variation can be reduced from 10.3 gf to 3.3 gf after mounting the active wire feed apparatus and the oscillation frequency is increased from 13 Hz to 21 Hz. The wire tension variation can be further reduced to 1.9 gf after mounting the MDVA on the system and the high frequency perturbation is significantly attenuated. The 30-deg corner cutting shows that the corner error are significantly reduced from 26.0 μm to 12.0 μm; the standard deviation of kerf is reduced from 4.34 μm to 0.96 μm, and the surface roughness Ra is reduced from 1.15 μm to 0.63 μm after employing both developed mechanisms.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

High Stable Mechanism Design for Micro-Wire Transport System in WEDM

2011 ◽  
Vol 189-193 ◽  
pp. 1366-1369
Author(s):  
Pi Wen Wang ◽  
Chun Hsien Yang ◽  
Mu Tian Yan
Keyword(s):  
Transport System ◽  
Electrical Discharge Machine ◽  
Sandwich Beam ◽  
Wire Tension ◽  
Stable Mechanism ◽  
Discharge Machine ◽  
The Wire ◽  
Wire Feeding ◽  
Inertial Loading ◽  
The Stability

A high stable wire transport system of wire-cut electrical discharge machine (WEDM) that can exercise the micro-wire machining is developed in this paper. In the wire transport system, two novel designs are proposed to improve wire tension variation during machining. 1. Active wire feeding unit: a device is used to isolate the inertia of the wire reel from the wire transport system. Hence the inertial loading of the wire can be reduced and the stability is also increased. 2. Multilayer sandwich vibration absorber: the axis of the reel is connected to a damped sandwich beam. When the perturbation occurs, the flexible motion of the beam can absorb the fluctuation of the wire. Then the wire tension can be more stable and better working precision is also achieved. Finally, two mechanisms were implemented on a micro wire-EDM machine to suppress the fluctuation of wire tension. Experimental results show that the variation of wire tension can be significantly reduced from 12.4 gf to 5.5 gf.

High-Speed Bonding of Resin-Coated Cu Wire and Sn Electrode with Ultrasonic Bonding for High-Frequency Chip Coil

2005 ◽  
Vol 297-300 ◽  
pp. 2819-2824 ◽  
Author(s):  
Ikuo Shohji ◽  
Tsukasa Sakurai ◽  
Shinji Arai
Keyword(s):  
Surface Roughness ◽  
High Frequency ◽  
High Speed ◽  
Bonding Process ◽  
Bonding Mechanism ◽  
Ultrasonic Bonding ◽  
Bonding Properties ◽  
The Wire ◽  
Bonding Method ◽  
Step Amplitude

High-speed ultrasonic bonding method has been developed to join resin-coated Cu wire on Sn electrodes for high-frequency chip coils. Two-step amplitude method, which decreases the ultrasonic amplitude in the bonding process, was effective to join the resin-coated Cu wire on Sn electrodes. The surface roughness treatment for a bonder head accelerated the deformation of the wire in the bonding process and improve the bondability compared to using the bonder head without that treatment. This paper also describes bonding properties of the joint and the bonding mechanism.

Analysis and Design of 3.3 kV IGBT Based Three-Level DC/DC Converter with High-Frequency Isolation and Current Doubler Rectifier

2009 ◽  
Vol 25 (25) ◽  
pp. 103-108
Author(s):  
Dmitri Vinnikov ◽  
Tanel Jalakas ◽  
Indrek Roasto
Keyword(s):  
High Voltage ◽  
High Frequency ◽  
Power Converter ◽  
Rolling Stock ◽  
Analysis And Design ◽  
Auxiliary Power ◽  
Igbt Modules ◽  
Isolation Transformer ◽  
New Generation ◽  
Generation Power

Analysis and Design of 3.3 kV IGBT Based Three-Level DC/DC Converter with High-Frequency Isolation and Current Doubler RectifierThe paper presents the findings of a R&D project connected to the development of auxiliary power supply (APS) for the high-voltage DC-fed rolling stock applications. The aim was to design a new-generation power converter utilizing high-voltage IGBT modules, which can outpace the predecessors in terms of power density, i.e. to provide more power for smaller volumetric space. The topology proposed is 3.3 kV IGBT-based three-level neutral point clamped (NPC) half-bridge with high-frequency isolation transformer and current doubler rectifier that fulfils all the targets imposed by the designers. Despite an increased component count the proposed converter is very simple in design and operation. The paper provides an overview of the design with several recommendations and guidelines. Moreover, the simulation and experimental results are discussed and the performance evaluation of the proposed converter is presented.

scholarly journals Analysis and Design of a Multi-Port DC-DC Converter for Interfacing PV Systems

Energies ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1943
Author(s):  
Bader N. Alajmi ◽  
Mostafa I. Marei ◽  
Ibrahim Abdelsalam ◽  
Mohamed F. AlHajri
Keyword(s):  
High Frequency ◽  
Computer Aided Design ◽  
Electromagnetic Transients ◽  
Pv System ◽  
Analysis And Design ◽  
Pv Systems ◽  
Point Tracking ◽  
Power Point Tracking ◽  
Power Point ◽  
Aided Design

A high-frequency multi-port (HFMP) direct current (DC) to DC converter is presented. The proposed HFMP is utilized to interface a photovoltaic (PV) system. The presented HFMP is compact and can perform maximum power point tracking. It consists of a high-frequency transformer with many identical input windings and one output winding. Each input winding is connected to a PV module through an H-bridge inverter, and the maximum PV power is tracked using the perturb and observe (P&O) technique. The output winding is connected to a DC bus through a rectifier. The detailed analysis and operation of the proposed HFMP DC-DC converter are presented. Extensive numerical simulations are conducted, using power system computer aided design (PSCAD)/electromagnetic transients including DC (EMTDC) software, to evaluate the operation and dynamic behavior of the proposed PV interfacing scheme. In addition, an experimental setup is built to verify the performance of the HFMP DC-DC converter.

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

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