A RSS Method for Estimating Hole Dimension Error in a Batch Micro-EDM Process

2007 ◽  
Author(s):  
J. J. Wang ◽  
J. L. Hou ◽  
F. C. Hsu ◽  
Y. Y. Liao ◽  
Steven Liang
Keyword(s):  
Geometric Dimension ◽  
Statistical Error ◽  
Dimensional Accuracy ◽  
Statistical Characteristics ◽  
Micro Edm ◽  
Production Environment ◽  
Fixed Dimension ◽  
Process Error ◽  
Hole Dimension ◽  
Edm Process

In an attempt to estimate the spread of errors in an EDM hole making process, a new Root-Sum-Square (RSS) method is proposed to combine the dimensional spread of a batch of electrodes with the over-cut variation in the micro-EDM process. Two sources of errors are commonly associated with an EDM process and contribute to the dimensional accuracy of the EDMed hole: the dimensional variation of the electrodes and the process over-cut error and its variation. Especially in a micro-EDM process, it is often difficult and time-consuming to measure the geometric dimension and tolerance of either a batch of electrodes or holes of small dimensions. By quantitatively establishing the relationship among the spreads in geometric errors of the electrodes and holes and the process capability, this new method provides an analytical tool in predicting hole error and allows allocating the tolerance budget when selecting the appropriate electrode making process, the EDM machine and process parameters. A series of experiments are carried out to establish and verify the RSS method. Given a set of EDM parameters and a batch of electrodes, the process error in the average over-cut and its spread is first obtained by the RSS method. The process error is then verified by separate experiments with electrodes of fixed dimension under the same EDM conditions. The validity of RSS method is further confirmed by experiments under different electrode dimensions. The RSS method is shown to well represent the contribution of both electrode and process errors to the statistical characteristics of the hole dimension. The establishment of this statistical error model should facilitate the design and control of hole quality by balancing the requirements for the dimensional accuracy of the electrodes and the process accuracy in a batch production environment.

MCDM-Based Optimization of Performance Characteristics During µEDMing of SS 304

2021 ◽  
pp. 18-32
Author(s):  
Premangshu Mukhopadhyay ◽  
Goutam Kumar Bose ◽  
Pritam Pain
Keyword(s):  
Stainless Steel ◽  
Work Performance ◽  
Research Work ◽  
Performance Characteristics ◽  
Micro Edm ◽  
Grey Relational Grade ◽  
Research Findings ◽  
Micro Features ◽  
Grey Relational ◽  
Edm Process

Micro-EDM is most widely used for developing perfect drilled micro features/parts. Research was carried out to improve the material removal and tool wear of any conductive machined product by EDM and micro-EDM process. In this chapter, RSM was used for designing the experiments with 20 set of experiments. In this present research work, performance characteristics like MRR and Overcut have got a different level of importance. Here the stress was given on MRR rather than on OC. In this MCDM analysis, the weight of MRR is considered to be maximum (i.e., larger is better), and other weights of other responses are considered to be the minimum (i.e., smaller is better). Finally, in the midst of all the combinations of process parameters considered one that acquires the highest grey relational grade is the best parametric combination. The research findings in the area of machining of stainless steel 304 will be helpful to manufacturing engineers for selecting the optimized parametric combinations of micro-EDM process with stainless steel.

Production of hard and lubricating surfaces on miniature components through micro-EDM process

2019 ◽  
Vol 105 (5-6) ◽  
pp. 1983-2000 ◽  
Author(s):  
Shalini Mohanty ◽  
Brij Bhushan ◽  
Alok Kumar Das ◽  
Amit Rai Dixit
Keyword(s):  
Micro Edm ◽  
Edm Process

Energetic consumption modeling of micro-EDM process

2017 ◽  
Vol 93 (5-8) ◽  
pp. 1843-1852 ◽  
Author(s):  
V. Marrocco ◽  
F. Modica ◽  
I. Fassi ◽  
G. Bianchi
Keyword(s):  
Micro Edm ◽  
Edm Process

Effects of Continuous Rolling Speed Change Rates on Geometric Dimension between Two Racks when Rolling Rail by Universal Pass

2012 ◽  
Vol 538-541 ◽  
pp. 2941-2944
Author(s):  
Yu Yan Liu ◽  
Yang Wang ◽  
Hu Zhu ◽  
Lin Chen
Keyword(s):  
Geometric Dimension ◽  
Dimensional Accuracy ◽  
Continuous Rolling ◽  
Distribution Law ◽  
Finite Element Software ◽  
Universal Mill ◽  
Speed Change ◽  
Rolling Deformation ◽  
The Relationship ◽  
Heavy Rail

This paper used the finite element software to simulate the process of the heavy rail rolling deformation between the UR and ER racks. It studied on the stress distribution law of the universal mill pass, the relationship between the universal mill unbalanced rates of velocity and tension changes of the rack, effect of the universal mill unbalanced rates of velocity on the change of the rolling geometric dimensions caused by the unbalanced rates of velocity. The research can guide the adjustment of the dimensional accuracy of the rail’s universal rolling.

Numerical and Experimental Study on Micro-Electrical Discharge Micromachining Characteristics on Molybdenum

2005 ◽  
Author(s):  
Phil Allen ◽  
Xiaolin Chen ◽  
Dave Kim
Keyword(s):  
Numerical Model ◽  
Electrical Discharge ◽  
High Energy ◽  
Spark Discharge ◽  
Discharge Process ◽  
Micro Edm ◽  
Micron Size ◽  
Mechanical And Physical Properties ◽  
Machining Characteristics ◽  
Edm Process

Electrical discharge micromachining (micro-EDM) is an ideal process for obtaining burr-free machined micron-size apertures. Molybdenum is one of the most attractive high energy and power aperture materials due to its mechanical and physical properties, mainly its high melting temperature and relatively high thermal conductivity. In this paper, fundamental machining characteristics for micro-EDM of molybdenum were investigated both numerically and experimentally. A thermo-numerical model was created to simulate a single spark discharge process. Experimental crater size is investigated using scanning electron microscopy and optical evaluation methods. The effects of important EDM parameters such as the pulse duration on crater shape, temperature distribution, tool wear percentage, and eroded volume were studied. Correlations between numerical and experimental data are also discussed. The model effectively estimates the size of single spark craters in molybdenum. The results show that the developed thermo-numerical model can be an effective tool in predicting the size of a crater formed by a single spark discharge in the micro-EDM process.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

scholarly journals A study of micro-electro discharge machining electrode wear

2007 ◽  
Vol 221 (5) ◽  
pp. 605-612 ◽  
Author(s):  
D T Pham ◽  
A Ivanov ◽  
S Bigot ◽  
K Popov ◽  
S Dimov
Keyword(s):  
Electrode Wear ◽  
Micro Edm ◽  
Volumetric Wear ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Electrode Shape ◽  
Compensation Methods ◽  
Geometrical Information ◽  
Edm Drilling ◽  
Edm Process

This paper studies the influence of factors contributing to electrode wear during the micro-electro discharge machining (EDM) process. The paper proposes a method for calculating the volumetric wear ratio based only on geometrical information obtained from the process. The objective of the work is to investigate the suitability of micro-EDM electrode wear compensation methods. Electrode shape deformation and random variations in the volumetric wear are studied as two main factors affecting the applicability of wear compensation methods as well as indicating the accuracy achievable with micro-EDM. EDM drilling and EDM milling are regarded as separate processes as they require different approaches in investigating and implementing the results of the study.

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