Micro-EDM Milling of Micro Compressor Prototype

2007 ◽  
Author(s):  
Zhenlong Wang ◽  
Yinghuai Dong
Keyword(s):  
Tool Path ◽  
Electrode Wear ◽  
Micro Edm ◽  
Simple Tool ◽  
Micro Power ◽  
Fast Development ◽  
Cad Cam ◽  
Rotor Disk ◽  
Micro Turbine ◽  
Cam Software

Micro power system is becoming more and more important for micro- and nano-scale system. The fast development of MEMS (Micro Electromechanical Systems) has strongly enhanced the application of new harder work materials. The fabrication of metallic 3D microstructures has been one of the most attractive topics of micro machining. Currently the basic materials of Micro-turbine Engineering were nonmetal materials such as SiC, most of them are 2D or quasi-3D structures. This paper focuses on the manufacturing process on micro compressor prototype by micro-EDM milling. The micro compressor prototype contains the rotor disk and stator disk. A simple tool path generation by CAD/CAM software and a general electrode wear compensation strategy is presented. The micro compressor prototype with rotor and stator disks was successfully fabricated by using this strategy, and the materials of workpieces are nickel alloy GH4169 and titanium alloy TC4.

Design and Fabrication of the Micro Turbine for Micro Gas Turbine Engine

2009 ◽  
Vol 69-70 ◽  
pp. 530-534 ◽  
Author(s):  
Ying Huai Dong ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Hui Chen ◽  
Wan Sheng Zhao
Keyword(s):  
Gas Turbine ◽  
Tool Path ◽  
Gas Turbine Engine ◽  
Electrode Wear ◽  
Micro Edm ◽  
Turbine Engine ◽  
Micro Gas Turbine ◽  
Cad Cam ◽  
Micro Turbine ◽  
Cam Systems

The designing of a micro turbine for micro gas turbine engine is presented in this paper. Micro power system is becoming more and more important for micro- and nano-scale system. The fast development of MEMS (Micro Electromechanical Systems) has strongly enhanced the application of new harder work materials. The fabrication of metallic 3D microstructures has been one of the most attractive topics of micro machining. Currently the basic materials of Micro-turbine Engineering were nonmetal materials such as SiC, most of them are 2D or quasi-3D structures. As a low cost, flexible, good repeatable machining process with negligible process forces, micro-EDM milling is well suited for freeform metallic micro structures. A three-dimensional micro turbine was fabricated by micro-EDM milling. A major problem in micro-EDM milling of complex 3D structure by using micro-electrode is the electrode wear. For reducing the impact of electrode wear, A new CAM system based on the UG software platform is developed in order to get good accuracy 2and higher efficiency. A simple tool path generation by CAD/CAM software and a general electrode wear compensation strategy is presented. The wear compensation can be apart from the design of CAD/CAM systems, so existing common CAD/CAM systems can be used to generate milling tool path with an unequal thickness lamination. And then post process for wear compensation and EDM milling can be done to modify tool path by adding wear compensation. The micro turbine blades of which the material is nickel alloy (GH4169) were successfully fabricated by using this strategy. The diameters of turbine are 2.8mm, and the height of each blade is 0.4mm.

Research on Chamfer Software of Complex Parts

2013 ◽  
Vol 631-632 ◽  
pp. 1335-1341
Author(s):  
Shi Yong ◽  
Wen Tao Liu
Keyword(s):  
3D Model ◽  
Tool Path ◽  
Machining Parameters ◽  
Cad Cam ◽  
Programming Software ◽  
A Chain ◽  
Definition Of ◽  
Complex Parts ◽  
Cam Software ◽  
Location Point

In order to meet the needs of enterprises for chamfering complex parts, based on the customization of commercial CAD/CAM software, chamfer programming software is developed. According to user’s machining demands for a part, a chain of edges of a part is extracted from its 3D model. With preprocessing of the chain of edges, the continuity of the chain is estimated, and the start and end point of those edges are automatic obtained. Furthermore, with human-machine dialogue, machining parameters is set by users. By definition of the primary and secondary surfaces of the chain of edges, and interpolation of the edges, the positions of cutter location point and postures of cutter are calculated. Finally the interference of tool path is checked, and tool path is simulated. The software solves the programming problem of chamfering complex parts.

CAD/CAM Integration System of 3D Micro EDM

2007 ◽  
Author(s):  
Hao Tong ◽  
Jing Cui ◽  
Yong Li ◽  
Yang Wang
Keyword(s):  
Real Time ◽  
Numerical Control ◽  
Machining Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Model Design ◽  
Integration System ◽  
Cad Cam ◽  
Micro Structures

In 3D scanning micro electro discharge machining (EDM), the CAD/CAM systems being used in mechanical milling of numerical control (NC) are unable to be applied directly due to the particularity of tool electrode wear. Based on industry computer and RT-Linux software platform, a CAD/CAM integration system of 3D micro EDM is developed. In the developed CAD/CAM integration system, the hardware includes mainly a micro feed mechanism for servo control, XY worktable, a high frequency pulse power supply, monitoring circuits etc., and the functions consist of model design, scanning path planning and simulation, NC code generation and post processing, real-time compensating of tool electrode wear, and machining control of states and process. The method of double buffer storage is adopted to transmit numbers of NC machining data. Servo scanning EDM method is used to realize real-time electrode wear compensating and thereby 3D micro structures are machined automatically. The machining experiments are made about model design, parameters optimizing, and process control. The typical 3D micro structures with space curved surfaces and lines have been machined such as micro prism, micro half tube, camber correlation line, and so on. The machining process and results show that the CAD/CAM integration system has the characters of higher real-time, reliability, and general using.

Study on 5-Axis Machining Key Technology of High-Precision Aluminum Alloy Integral Impeller

2009 ◽  
Vol 69-70 ◽  
pp. 433-436
Author(s):  
X.J. Wang ◽  
S.L. Li ◽  
Can Zhao
Keyword(s):  
Aluminum Alloy ◽  
Path Planning ◽  
Machine Tool ◽  
Tool Path ◽  
Tool Path Planning ◽  
Process Plan ◽  
Key Technology ◽  
Aero Engine ◽  
Cad Cam ◽  
Cam Software

Using the typical CAD/CAM software UG, an aero-engine integral impeller was studied in this paper, including 3-D modeling, tool-path planning and simulation. A regular impeller was machined with a 5-axis machine tool, which showed the process plan was feasible.

The Closed Impeller Milling Avoidance Programming Algorithm

2013 ◽  
Vol 753-755 ◽  
pp. 1270-1273
Author(s):  
Quan Liang ◽  
Dong Hai Su ◽  
Jie Wang ◽  
Ye Mu Wang
Keyword(s):  
Path Planning ◽  
Configuration Space ◽  
Tool Path ◽  
Programming Algorithm ◽  
3D Space ◽  
Collision Problem ◽  
Cad Cam ◽  
Cutting Path ◽  
Cam Software ◽  
2D Space

An automatically correction algorithm was promoted to solve the problem that most of the commercial CAD/CAM software can only detect the collision, but can not generate collision-free tool path on cutting path planning. The algorithm uses the configuration space theory to map the boundary into the 2D configuration space, and then the 3D space interference collision problem was transformed into 2D space. Finally, the algorithm was used to generate cutting path of a closed impellers runner. From the result of cutting path planning, the proposed algorithm was able to avoid the interference in the process of tool path planning about closed impeller.

Research on Electrode Wear Prediction and Compensation On-Line Technology for Micro EDM Application

2008 ◽  
Vol 392-394 ◽  
pp. 166-171
Author(s):  
Yong Zhang ◽  
Zhen Long Wang ◽  
Z.Y. Li ◽  
Wan Sheng Zhao
Keyword(s):  
Three Dimensional ◽  
Electrode Wear ◽  
Micro Edm ◽  
3D Structures ◽  
Cad Cam ◽  
Discharge Status ◽  
On Line ◽  
Line Technology ◽  
Special Cad ◽  
Micro Structures

A micro-EDM equipment which can fabricate three-dimensional micro-structures is developed. A method of electrode wear compensation on-line which is very important to micro 3D structures machined by micro-EDM is presented. In this method, the wear of electrode can be predicted by the statistics law of open rate of discharge status, therefore, its precise model which is very difficult to build as well as the special CAD/CAM system is hardly necessary. At the same time, the micro-EDM CAD/CAM technology which applies the universal CAD/CAM software for milling is also researched and experienced on Unigraphics (UG). At last, micro 3D structures, a micro hemisphere with diameter ∅150+m and a micro 3D beam which is very popular in MEMS, are machined on silicon wafer by this way, which proves the wide useful of this method and the promising application in MEMS.

Additive Manufacturing Bead Deposition Based Rotary Tool Path Applications

2018 ◽  
Author(s):  
Ruth Jill Urbanic ◽  
Bob Hedrick
Keyword(s):  
Additive Manufacturing ◽  
Tool Path ◽  
Thermal Spraying ◽  
Direct Energy Deposition ◽  
Tool Paths ◽  
Rotary Tool ◽  
Rotationally Symmetric ◽  
Direct Energy ◽  
Cad Cam ◽  
Cam Software

Additive manufacturing layer-based solution approaches have been applied for several technologies and systems. Process planning solutions are being developed for planar applications, but rotary applications can benefit from an additive manufacturing ‘rotary layering’ strategy as well. There are systems that have been developed to coat pipes and other rotationally symmetric components, and there are multi-axis applications that would require rotary-like tool paths. Developing and exploring additive rotary tool path applications is the focus of this research. These initial solutions will be applicable for direct energy deposition and thermal spraying models. AM rotary proof of concept tool paths are developed using a commercial CAD/CAM software, and a software development kit (SDK). Selected case studies are presented, with varying levels of geometric complexity.

Distributed Integration of Knowledge-Based Process Planning With CAM Software

2004 ◽  
Author(s):  
Dusan N. Sormaz ◽  
Narender Neerukonda ◽  
Vikesh Jain
Keyword(s):  
Process Planning ◽  
Manufacturing Systems ◽  
Tool Path ◽  
Planning System ◽  
Rule Base ◽  
Seamless Integration ◽  
Rule Based ◽  
Traditional Mode ◽  
Cad Cam ◽  
Cam Software

Seamless integration of manufacturing planning activities, though being imperative for application of advanced technologies, is still not completely developed. Integration between design and manufacturing systems is usually done within tightly implemented suite of CAD/CAM applications. However, there is a need to integrate these applications into a wider framework in which manufacturing knowledge is incorporated into planning tasks, and tasks may be executed in distributed environment. This paper proposes such a framework. The methodology is based on integration of CAM software with rule-based process planning on several levels. The basis for this approach is existence of feature based CAD model that is usually designed in CAD package. The process-planning task can be performed in two modes: traditional mode and distributed mode. In traditional mode, tightly integrated CAM package is used to create necessary tool paths and detailed specification for particular geometry from the design. They are exported into a CAPP package for cost optimization and sequencing for the final NC program. Distributed mode allows utilization of rule base for creation of manufacturing operations. Results are imported into CAM package for tool path generation and NC code post processing. CAD/CAM package exports its feature into rule-based process planning system. For each feature, rules are fired in order to select the most appropriate machining operation, tool, and cutting parameters. Process sequencing can also be performed. In both modes, integration may be carried out between different computers using TCP/IP protocol to enable distributed processing of different tasks. The current results in implementing the prototype, which supports proposed methodology and few test cases of both operating modes, are also described.

An Integrated CAD/CAM System for Design and Manufacturing of High-Curvature Surfaces

1999 ◽  
Author(s):  
Liping Wang ◽  
Subramaniam S. Nair
Keyword(s):  
New York ◽  
Tool Path ◽  
Rear View Mirror ◽  
City College ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Filling Analysis ◽  
Five Axis ◽  
The City ◽  
Cam Software

Abstract This paper presents an integrated CAD/CAM system developed at the City College of the City University of New York (CCNY) for design, analysis and manufacturing of high-curvature surfaces. Surface modeling technique which is characterized by modeling from curvature or slope information, is discussed and practiced to design high-curvature surfaces such as rear-view mirror covers for automobiles. Plastic molding is chosen to manufacture the designed parts. Molding parameters such as entrance position and mold inserts are analyzed and determined using tools such as mold filling analysis (C-FLOW/EZ). Newly modified curvature matching method, together with methods provided by commercial CAM software, are adopted to generate five-axis NC tool path to manufacture the designed mold components. An example on design and manufacturing of a rear-view mirror cover using the integrated CAD/CAM system for high-curvature surfaces is given to illustrate the effectiveness of this system.

Recent Patents on Micro-EDM Milling

2020 ◽  
Vol 13 (3) ◽  
pp. 219-229
Author(s):  
Baocheng Xie ◽  
Jianguo Liu ◽  
Yongqiu Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Processing Method ◽  
Electrode Wear ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Processing Methods ◽  
Machining Quality ◽  
Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

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