Investigation on Wire Electrochemical Micro Machining

2007 ◽  
Author(s):  
Kun Wang ◽  
Di Zhu ◽  
Ningsong Qu
Keyword(s):  
Control System ◽  
Real Time ◽  
Machining Accuracy ◽  
Micro Machining ◽  
Wire Electrode ◽  
Micro Structure ◽  
Nanosecond Pulses ◽  
Machining System ◽  
Micrometer Scale ◽  
Micro Wire Electrode

Wire electrochemical micro machining (WEMM) using the online-fabricated micro wire electrode is proposed as a new method of micro machining. Based on electrochemical principle, the mechanism of nanosecond pulses WEMM was investigated. The hardware of the control system was founded using devices of virtual instruments, and the software of the system was designed based on Labwindows/CVI. The micrometer scale wire electrode was online fabricated, the diameter of wire electrode was real-time monitored by precisely measuring the variation in resistance of the electrode, and it is possible that accomplish the fabrication of wire electrode and the following processes continuously in the same machining system. The relations between the machining accuracy and parameters, such as velocity of feed forward and pulses parameters was experimentally studied, and a series of high-aspect-ration micro structure and multi-microgrooves were fabricated. The research of the paper sets up a firm foundation for application of the proposed wire electrochemical micro-machining.

Experiment Study on Micro-Seam in Electrochemical Machining

2013 ◽  
Vol 584 ◽  
pp. 15-19
Author(s):  
Zhi Yong Li ◽  
Pei Yu Dong ◽  
Yi Gang Wang
Keyword(s):  
Applied Voltage ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Micro Machining ◽  
Wire Electrode ◽  
Process Stability ◽  
Electrode Shape ◽  
The Wire ◽  
Better Than

In this study, we firstly developed a numerical electrochemical micro-machining (EMM) setup. Furthermore, the effects of five vital process parameters, applied voltage, electrolyte type, electrode shape and diameter, electrode feed rate on micro-seams machining accuracy and process stability were evaluated. The experimental results show that: Wire electrodes machining accuracy is higher than that of sheet electrode. With the wire electrodes diameter decreased from 0.2mm to 0.06mm, micro-seam width is reduced by 36.55%. With the wire electrode feed rate increased from 0.2mm/min to 0.6mmm/min, micro-seam width is reduced by 44.2%. Sheet electrodes machining stability is better than that of wire electrode. The number of machining stability of sheet electrode is 25% higher than that of wire electrode in the condition of 8V applied voltage.

Servo Scanning EDM for 3D Micro Structures

2007 ◽  
Author(s):  
Yong Li ◽  
Hao Tong ◽  
Jing Cui ◽  
Yang Wang
Keyword(s):  
Real Time ◽  
Servo Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Electrode Wear ◽  
Layer By Layer ◽  
Machining System ◽  
Scanning Path ◽  
Micro Structures ◽  
Discharge Gap

In electro discharge machining (EDM) for 3D micro structures, the electrode wear is serious and it needs to be compensated in process. To obtain a better balance of the machining accuracy and efficiency, a servo scanning EDM method is proposed for 3D micro structures, in which the electrode wear is compensated on real-time by controlling the discharge gap constant. It is supposed reasonably that the machining depth of each layer in servo scanning EDM is consistent if discharge gap is kept preferably. The servo scanning EDM strategies include the model design by Pro/Engineer (Pro/E), the plan and simulation of scanning path, and the machining process. The 3D micro structures are machined by scanning layer-by-layer under servo control of the electrode with monitoring discharge gap signal. The CAM, gap servo control, and real-time electrode wear compensating are integrated into the machining system. The evaluation experiments of servo scanning EDM and the typical machining experiments of 3D micro structures have been carried out. The machining results show that the electro discharge in the servo scanning EDM is more stable. Servo scanning micro EDM is propitious to improve machining accuracy and efficiency in 3D micro structures.

Study and Application on Ultrasonical Combined Electrical Micro-Machining the Special Shape Micro-Structures

2013 ◽  
Vol 313-314 ◽  
pp. 711-716
Author(s):  
Yong Wei Zhu ◽  
Yu Ren Du ◽  
Xing Lei Miao ◽  
Nai Zhang Yun
Keyword(s):  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Micro Machining ◽  
Special Shape ◽  
Friction Units ◽  
Machining System ◽  
Hard And Brittle Materials ◽  
Low Amplitude ◽  
Micro Structures

For manufacturing the special shape micro-structures with hard and brittle materials , the ultrosonical combined electrical micro-machining method is proposed and improved. The ultrasonical combined synchronous electrochemical micro-machining system is built and optimized, which machining parameters can be adjusted in a big ranges, and the synchronous target between the ultrasonical vibration and the voltage of micro-PECM(Micro-pulse electrochemical machining) can be realized. The micro-machining electrodes are manufactured in round sections by combined micro electrical-discharged machining (EDM).The mechanism tests of ultrasonic vibration combined electrical pulse micro-machining tests are carried. It is adopted that the low amplitude of electrical voltage (no more than 6V) and the static electrolyte with lower electrical conduction rate, the good machining accuracy and surface quality are acquired. The regular morphology array micro-round holes are manufactured successfully on friction units' working surface, which can save oil , improve the friction performances and prolonging working life of important friction units. In additional, the fixed holes satisfying the precision needs are machined on the hard and brittle piezo-ceramics pieces, which are often used in many important micro-precise piezo-ceramics sensor. It is proved that ultrasonic combined electrical micro-machining is an effect method for to machine the special shape micro-structures.

Control-Oriented Modeling of Thermal Deformation of Machine Tools Based on Inverse Solution of Time-Variant Thermal Loads with Delayed Response

2004 ◽  
Vol 126 (2) ◽  
pp. 286-296 ◽  
Author(s):  
S. Fraser ◽  
M. H. Attia ◽  
M. O. M. Osman
Keyword(s):  
Control System ◽  
Real Time ◽  
Thermal Deformation ◽  
Heat Conduction Problem ◽  
Integrated System ◽  
Machining Accuracy ◽  
Delayed Response ◽  
Frequency Noise ◽  
Real Time Control ◽  
Time Control

With the new emerging technologies of high performance machining and the increasing demand for improved machining accuracy in recent years, the problem of thermal deformation of machine tool structures is becoming more critical than ever. The major problem in implementing real-time control systems is the difficulty of measuring the relative thermal displacement between the tool and the workpiece during machining. Therefore, the design of a generic multi-axis control system requires the development of control-based models to estimate the transient thermal load and the thermal deformation of the structure in real-time. To satisfy the stringent accuracy and stability requirements of the control system, a new inverse heat conduction problem IHCP solver is developed. This solution is capable of including the inertia effect and the delay in the thermal response, in order to accommodate situations where the measured points cannot be located near the heat source, which may be buried into the structure. Experimental validation of these models showed their inherent stability even when the temperature measurements are contaminated with random errors. The excellent computational efficiency of the integrated system, which is well suited for real-time control applications involving multi-dimensional structures, was achieved by incorporating an inverse numerical Laplace transformation procedure. The results also showed that the thermal deformation transfer function behaves as low-pass filters, and as such it attenuates the high frequency noise associated with temperature measurement error.

Control-Oriented Modeling of Thermal Deformation of Machine Tools Based on Inverse Solution of Time-Variant Thermal Loads With Delayed Response

Manufacturing ◽  
2003 ◽  
Author(s):  
S. Fraser ◽  
M. H. Attia ◽  
M. O. M. Osman
Keyword(s):  
Control System ◽  
Temperature Measurement ◽  
Real Time ◽  
Thermal Deformation ◽  
Integrated System ◽  
Machining Accuracy ◽  
Delayed Response ◽  
Frequency Noise ◽  
Real Time Control ◽  
Time Control

With the new emerging technologies of high performance machining and the increasing demand for improved machining accuracy in recent years, the problem of thermal deformation of machine tool structures is becoming more critical than ever. The major problem in implementing real-time control systems is the difficulty of measuring the relative thermal displacement between the tool and the workpiece during machining. Therefore, the design of a generic multi-axis control system requires the development of control-based models to estimate the transient thermal load and the thermal deformation of the structure in real-time. To satisfy the stringent accuracy and stability requirements of the control system, a new inverse heat conduction problem IHCP solver is developed. This solution is capable of including the inertia effect and the delay in the thermal response, in order to accommodate situations where the measured points cannot be located near the heat source, which may be buried into the structure. Experimental validation of these models showed their inherent stability even when the temperature measurement are contaminated with random errors. The excellent computational efficiency of the integrated system, which is well suited for real-time control applications involving multi-dimensional structures, was achieved by incorporating an inverse numerical Laplace transformation procedure. The result also showed that the thermal deformation transfer function behaves as low-pass filters, and as such it attenuates the high frequency noise associated with temperature measurement error.

Development of real time welding control system by using image processing.

1989 ◽  
Vol 7 (3) ◽  
pp. 363-367 ◽  
Author(s):  
Takaichi Koyama ◽  
Yoichi Takahashi ◽  
Masahiro Kobayashi ◽  
Junichiro Morisawa
Keyword(s):  
Image Processing ◽  
Control System ◽  
Real Time
Sign in / Sign up

Export Citation Format

Share Document