scholarly journals Research on Shape Change of Multimaterial Electrode for EDM

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Wenjian Wang ◽  
Yu Liu ◽  
Wenchao Zhang ◽  
Fujian Ma ◽  
Dapeng Yang ◽  
...  
Keyword(s):  
Material Removal ◽  
Shape Change ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Machining Process ◽  
Die Steel ◽  
Electrode Shape ◽  
Simulation Strategy ◽  
Feed Strategy ◽  
Simulation Results

The shape change law of a multimaterial electrode in EDM was studied, and a cosimulation between ANSYS and MATLAB of electrode shape change of the multimaterial electrode and workpiece was established. Element birth and death in ANSYS was used to obtain the removal volume in a single-pulse discharge, and the electrode feed strategy, material removal, and renewal strategy are considered to establish the shape simulation strategy. Then, a program based on MATLAB software was compiled to simulate the machining process and predict the shape change of the multimaterial electrode of different combinations. The experiments of different multimaterial electrodes were carried out with the die steel as the workpiece. The simulation results were compared with the experimental results to verify the effectiveness of the simulation model.

scholarly journals Simulation of Material Removal Process in EDM with Composite Tools

2019 ◽  
Vol 2019 ◽  
pp. 1-11 ◽  
Author(s):  
Shengfang Zhang ◽  
Wenchao Zhang ◽  
Puyong Wang ◽  
Yu Liu ◽  
Fujian Ma ◽  
...  
Keyword(s):  
Material Removal ◽  
Electrical Discharge Machining ◽  
Single Pulse ◽  
Die Steel ◽  
Composite Tool ◽  
Discharge Parameters ◽  
Material Removal Model ◽  
Simulation Results ◽  
Removal Model ◽  
Single Material

With the development of (electrical discharge machining) EDM technology, composite tools with special features gradually replace the traditional single-material tools and have become widely used in specific processing conditions. In order to predict the wear of composite tool effectively, in this paper, a material removal model of single-pulse EDM with composite tools was established by using the finite element method. The surface temperature distribution of the composite tool was obtained by taking the copper-die steel tool as the analysis object. And the shape of discharge crater as well as the removal volume was obtained by the element birth and death method. The influences of discharge parameters and tool materials on the removal volume were analyzed respectively. The EDM experiments were carried out by using copper-die steel as the composite tool to verify the simulation results. It shows that the errors between actual machining results and the simulation results are less than 10%, which proves the accuracy of the simulation model.

Process Simulation of Electrochemical Machining of Convexity Structure on Revolving Workpiece

2015 ◽  
Author(s):  
Zengwei Zhu ◽  
Dengyong Wang ◽  
Jun Bao ◽  
Di Zhu
Keyword(s):  
Mathematical Model ◽  
Process Simulation ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Relative Rotation ◽  
Electrode Gap ◽  
Simulation Results

A special electrochemical machining (ECM) process using a revolving cathode tool with hollow windows is presented. Unlike conventional sinking ECM, this presented ECM process fabricates the convexity structures on a revolving part by the relative rotation of anode workpiece and cathode tool. In this paper, a mathematical model is established to describe the evolution of the machining process, the finite element simulations of the new forming fashion are focused for the workpiece’s revolving surface and the convexity’s side profile. The simulation results show that both the cathode feed rate and the applied voltage have significant influence on the equilibrium inter-electrode gap and the material removal rate. The side profile of the convexity is related to radius of the cathode tool. It is expected that the equilibrium gap and steady removal rate could be achieved by optimizing the cathode feed rate and the voltage, the required side profile taper of the convexity could be obtained by selecting the proper tool radius.

Analysis and Simulation of Micro Electro Discharge Machining Process

2007 ◽  
Author(s):  
Dedong Gao ◽  
Ling Tian
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Machining Process ◽  
Micro Edm ◽  
Analysis Model ◽  
Element Analysis ◽  
Electro Discharge Machining ◽  
Numeric Simulation

Based on the basic thermal conductivity theory and the fact of micro electro discharge machining (micro-EDM), a finite element analysis model of micro-EDM is proposed. Through finite element analysis software ANSYS, the temperature field distribution of the single pulse discharge is simulated under the different heat source condition. It can be seen from the results that the shape of discharge crater is similar to that of molten zone of the temperature distribution. The surface roughness and material removed rate of single pulse discharge are calculated and analyzed by the numeric simulation results.

scholarly journals Observation of Material Removal Process by Single Pulse Discharge in Air

2018 ◽  
Vol 52 (129) ◽  
pp. 31-37 ◽  
Author(s):  
Takayuki TANI ◽  
Yoshiki TSUJITA ◽  
Hiromitsu GOTOH ◽  
Naotake MOHRI
Keyword(s):  
Material Removal ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Removal Process

Research on Simulation of Virtual NC Lathe Machining Process

2014 ◽  
Vol 552 ◽  
pp. 381-386
Author(s):  
Li Bo Zhou ◽  
Fu Lin Xu ◽  
Zhi Xiong Shen
Keyword(s):  
High Efficiency ◽  
Physical Simulation ◽  
Shape Change ◽  
Strain Analysis ◽  
Machining Process ◽  
Machining Parameters ◽  
Nc Code ◽  
Cnc Programming ◽  
Simulation Functions ◽  
Simulation Results

Virtual NC lathe machining simulation system is carried out with Visual C++ and Open Inventor software. The system possesses visible UI, interactive inputting workpiece and machining parameters, the integration of geometric simulation and physical simulation, all the simulation functions including real-time display machining process, tool moving, workpiece geometry shape change, the generation and movement of iron simulation, workpiece pressure shape change could be realized. Tool temperature analysis and stress & strain analysis are simulated in the cutting process by FEM. The simulation results show the high efficiency of the simulation algorithm, reasonable simulation results, lifelike. The practice and training could be replaced by the virtual one. The system is applied to verification of NC code, quality evaluation of machine operators, operators, CNC programming staff training and other functions.

Gap Phenomena of Ultrasonic Vibration Assisted Electrical Discharge Machining in Gas

2008 ◽  
Vol 375-376 ◽  
pp. 500-504
Author(s):  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Shu Peng Su ◽  
Qing Gao
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Environment Pollution ◽  
Dielectric Fluids ◽  
Simple Tool ◽  
Spark Plasma

Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is a new machining technology developed in recent years. This technology uses air or oxygen as dielectric and ultrasonic vibration is applied to the workpiece during machining. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also has virtues of wide applications, high machining efficiency, and simple tool electrodes and so on. In this paper, the formation and transformation of the spark plasma and the mechanism of material removal during a single pulse discharge are introduced.

Simulation of Debris Movement in Micro Electrical Discharge Machining of Deep Holes

2009 ◽  
Vol 626-627 ◽  
pp. 267-272 ◽  
Author(s):  
Jin Wang ◽  
Yuan Gang Wang ◽  
Fu Ling Zhao
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Electrode Shape ◽  
Machining Speed ◽  
Debris Transport ◽  
Simulation Results

In micro electrical discharge machining (micro-EDM) of deep holes, the debris dispersed in gap may increase the possibility of secondary discharge, resulting in electrode shape changing and low accuracy of machined hole. In this paper, the debris movement caused by flow fluid in the machining gap is analyzed to understand the mechanism of debris transport by using software, FLUENT. Comparison of debris movement calculated by the modified N-S equation and N-S equation is conducted. Debris movement calculated by the modified N-S equation is demonstrated to be correct by experiment. The simulation results can explain the phenomena such as subulate electrode and hole, unstable machining process and low machining speed in micro-EDM of deep holes. It is helpful to improve the process of micro-EDM.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

scholarly journals Simulation of the ductile machining mode of silicon

2021 ◽  
Author(s):  
Hagen Klippel ◽  
Stefan Süssmaier ◽  
Matthias Röthlin ◽  
Mohamadreza Afrasiabi ◽  
Uygar Pala ◽  
...  
Keyword(s):  
Brittle Material ◽  
Material Removal ◽  
Machining Process ◽  
Ductile Material ◽  
Diamond Wire ◽  
Ductile Machining ◽  
Mesh Free ◽  
Diamond Wire Sawing ◽  
Material Removal Mode ◽  
Brittle Material Removal

AbstractDiamond wire sawing has been developed to reduce the cutting loss when cutting silicon wafers from ingots. The surface of silicon solar cells must be flawless in order to achieve the highest possible efficiency. However, the surface is damaged during sawing. The extent of the damage depends primarily on the material removal mode. Under certain conditions, the generally brittle material can be machined in ductile mode, whereby considerably fewer cracks occur in the surface than with brittle material removal. In the presented paper, a numerical model is developed in order to support the optimisation of the machining process regarding the transition between ductile and brittle material removal. The simulations are performed with an GPU-accelerated in-house developed code using mesh-free methods which easily handle large deformations while classic methods like FEM would require intensive remeshing. The Johnson-Cook flow stress model is implemented and used to evaluate the applicability of a model for ductile material behaviour in the transition zone between ductile and brittle removal mode. The simulation results are compared with results obtained from single grain scratch experiments using a real, non-idealised grain geometry as present in the diamond wire sawing process.

Schruppfräsbearbeitung von Verdichterscheiben/Milling of compressor disk - Identification of a cutting material and coating combination for high process reliability

2017 ◽  
Vol 107 (09) ◽  
pp. 674-680
Author(s):  
E. Prof. Abele ◽  
C. Hasenfratz ◽  
C. Praetzas ◽  
G. M. Schüler ◽  
C. Stark ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Manufacturing Technology ◽  
Machining Process ◽  
Complex Task ◽  
Eine Hohe ◽  
Process Reliability ◽  
Rough Milling ◽  
Compressor Disk

Die Herstellung von Verdichterscheiben stellt hohe Ansprüche an die Fertigungstechnik. Neue, schwer zu zerspanende Materialien und Integralkonstruktionen erzeugen eine hohe Komplexität bei der Ausführung. Das Projekt „SchwerSpan“ stellt sich dieser Herausforderung und entwickelt einen Prozess zur Schruppfräsbearbeitung von Verdichterscheiben. Ziel des Projekts ist eine Reduktion der Werkzeugkosten bei erhöhtem Zeitspanvolumen.   The production of compressor disks places high demands on the manufacturing technology. A very complex task is created by new difficult-to-cut materials and integral components. The project “SchwerSpan” is taking on this task by developing a machining process for rough milling in the production of compressor disks. The aim of the process is to reduce the tool costs by increasing material removal rate.

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