High Speed Wire Electrical Discharge Machining*/High-Speed Wire Electrical Discharge Machining - An explorative study of a hybrid electro machining process

2016 ◽  
Vol 106 (06) ◽  
pp. 430-438
Author(s):  
K. Prof. Oßwald ◽  
D. Murnberger ◽  
T. Kappler ◽  
G. Sedlmayr
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Work Piece ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Industrialized Countries ◽  
Explorative Study ◽  
Electro Discharge Machining

Diese Untersuchung beschäftigt sich mit einer in den westlichen Industrienationen kaum bekannten Variante des Drahterodierens. Es wird zunächst ein Überblick über die Merkmale der Technologie (beispielsweise Aufbau, verwendeter Draht, Prozessflüssigkeit) gegeben, die sich teilweise deutlich von der konventionellen Technik unterscheiden. Des Weiteren werden die Verläufe von Strom und Spannung des Prozesses gemessen sowie die gefertigten Werkstückoberflächen untersucht.   This study deals with a variant of Wire Electrical Discharge Machining that is barely known in western industrialized countries. An overview of this technology‘s characteristics (setup, wire, fluid) is given, some of which are significantly different from conventional wire EDM (Electro Discharge Machining) technology. Furthermore, current and voltage profiles of the HSWEDM (High Speed Wire Electrical Discharge Machining) pulses are analyzed as well as the machined work piece surfaces.

Wire Electrical Discharge Machining – High Speed VS Abrasive Waterjet - A Case Study

2011 ◽  
Vol 189-193 ◽  
pp. 4245-4255
Author(s):  
Shi Jin Zhang ◽  
Yu Qiang Wu ◽  
Yan Li Wang
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Wire Electrical Discharge Machining ◽  
Technological Advancement ◽  
Proper Selection ◽  
Regular User

Technological advancement, on the one hand, made Electrical Discharge Machining (EDM) much faster. One example of that is the presence of Wire Electrical Discharge Machining – High Speed (WEDM-HS) machine, which makes the material removal rate as high as 80 . On the other hand, it also made Abrasive Waterjet (AWJ) achieve much better quality surface and tighter tolerance. As a result, these two types of machining process have converged to the point where they can complement one another quite nicely in selected applications. However, it does not mean user may pick any one for their applications. The proper selection not only decreases the manufacturing costs but also achieves better quality. This paper focuses on comparing WEDM-HS with AWJ by actually cutting a special designed sample. Through comparison from several aspects which include dimension precision, surface roughness, cost, cutting time and surface damage, a proper selection guidance for regular user has been provided.

Development of the Cylindrical Wire Electrical Discharge Machining Process

2001 ◽  
Author(s):  
Jun Qu ◽  
Albert J. Shih ◽  
Ron Scattergood
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Free Form ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Cylindrical Workpiece ◽  
Cylindrical Wire

Abstract Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of an underwater rotary spindle is first introduced. The spindle is added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometry. Mathematical models for material removal rate and surface finish in cylindrical wire EDM of the free-form cylindrical workpiece are derived. Experiments are conducted for cylindrical and 2D wire EDM of brass and carbide work-materials. Comparing to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates could be achieved in the cylindrical wire EDM. The surface finish and roundness of parts generated by cylindrical wire EDM at different part rotational speeds and wire traverse speeds are measured and analyzed.

Modeling and Optimization of Micro Electro Discharge Machining Process: A Review

2012 ◽  
Vol 622-623 ◽  
pp. 590-594 ◽  
Author(s):  
P. Sivaprakasam ◽  
P. Hariharen ◽  
S. Kathikheyen ◽  
S. Balusamy
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Work Piece ◽  
Machining Performance ◽  
Micro Electrical Discharge Machining ◽  
Electro Discharge Machining ◽  
Short Period

Micro Electrical discharge machining (µEDM) is an electro thermal process, the cutting force is negligibly small and material removal occurs irrespective of hardness of work piece material .Micro electrical discharge machining process is capable of machining of complex shape, which is difficult to machine in conventional machining process. Last decade, the EDM process involved demand for machining requirements with short period. Since the major risk of wire breakage, deflections of electrodes were affecting the performance accuracy of EDM operation. This paper describe about a comprehensive review of micro electro discharge machining process and its process optimization techniques used for last 10 years. Micro electro discharge machining has more important given to difficult to machine materials. In order to improve the surface integrity and performance of process, need to select proper process parameters. It reports on the Micro EDM research involving the optimization of the process parameters surveying the influence of the various factors affecting the machining performance and productivity.

Analysis of Micro-Pin Manufacturing Using Inverse Slab Electrical Discharge Milling (ISEDM) Process

2011 ◽  
Vol 496 ◽  
pp. 247-252 ◽  
Author(s):  
Ruben Gil ◽  
J.A. Sánchez ◽  
N. Ortega ◽  
S. Plaza ◽  
B. Izquierdo ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Work Piece ◽  
Electrode Wear ◽  
Pulse Off Time

Abstract. This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), using a conventional EDM machine and graphite electrode. The effect of pulse off-time, work piece final diameter and machining length on material removal rate, electrode wear ratio, radial accuracy and surface roughness has been quantified. From the study, optimum strategies that involve the use of different EDM regimes for achieving the optimum requirements can be defined. Micro-pins of 0.3 mm diameter with aspect ratio as high as 100:1 have been successfully manufactured.

Wire Electrical Discharge Machining (Wire EDM) Cutting of Flexures for a Rotary Flexural Bearing Fabrication

2011 ◽  
Vol 314-316 ◽  
pp. 1727-1733
Author(s):  
Hong Ping Luo ◽  
Zhi Xiong Zhou ◽  
Yong Jun Zhang ◽  
Zhong Ning Guo
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Torsional Stiffness ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Factors Affecting ◽  
Before And After ◽  
Cutting Sequence

Wire electrical discharge machining (Wire EDM) cutting of flexures for a rotary flexural bearing fabrication is developed. The results of FEA calculation and theoretical analysis show that one of the main factors affecting flexures’ machining is the weak torsional stiffness of the bearing cage, thus excessive deflections due to machining stress, heat generation and spark-induced vibrations may occur. To minimize flexure deflection during the machining process, a specially designed fixture is utilized. Other technical measures, including residual stress relief before and after Wire EDM cutting, reasonable cutting sequence planning, multiple-cutting (i.e., rough cut followed by several trim cuts) etc., are also adopted for cutting. Dimensional accuracy of ±5µm was obtained over the 150µm thickness for the bearing flexures, a variation of less than 3µm was achieved for the flexures of opposing sides, and surface roughness of better than Ra 0.3μm was obtained for the flexures of the entire bearing cage. These results show the validity of measures aforementioned.

scholarly journals A Research on Machinability of Bio Implant by Electric Discharge Machining Process

2019 ◽  
Vol 8 (4S2) ◽  
pp. 260-263
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Work Piece ◽  
Implant Materials ◽  
Hard Materials ◽  
Electro Discharge Machining ◽  
Current Scenario ◽  
Conventional Machine ◽  
Increasing Demand

Increasing demand in industries to manufacturing the complex geometric shape and hard materials parts is extremely difficult to cut by the conventional machining process. The non-conventional machine is used for the manufacturing of 3D complex and geometry shapes without compromise the required specification. Electro discharge machining (EDM) is a non-traditional machining process, which is very widely used in recent days. EDM process is electrical and thermal energy generated between work piece and an electrode. The major applications are dies, moulds, aerospace parts, automotive industry, and surgical components. The human implant materials like Stainless Steel, Titanium and Co-Cr based alloys are widely used in biomedical fields. This paper shows that fundamental studies on electrical discharge machining (EDM), Wire electrical discharge machining (WEDM) and human implant materials with newly developed advance technologies in the current scenario.

Multi-Response Optimisation of Cutting Parameters of Wire EDM in Titanium Using Response Surface Methodology

2016 ◽  
Vol 854 ◽  
pp. 93-100 ◽  
Author(s):  
B. Sivaraman ◽  
Senthil Padmavathy ◽  
P. Jothiprakash ◽  
T. Keerthivasan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Work Piece ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Control Parameters

This Aim of this paper is to analyse the effect of machining parameters of wire electrical discharge machining (WEDM) on workpiece material titanium, that were now widely used in many applications because of its technical benefits. Conventional method of machining the material will make the work piece to crack or flaws due to chipping, presence of burrs and cracking. Wire cut Electrical discharge machining techniques have been already tried with some other high strength materials which is complicated to cut. To prove the feasibility of machining the titanium, many experiments were carried out based on RSM. Hence by the head wire electrical discharge machining process is to be used to machining the work piece material (titanium) and the effect of various control parameters on the response parameters were analysed and optimized and the optimal combination of control parameters were found to get higher metal removal rate and surface finish using Response Surface Methodology.

Microstructural Characterization of Thermal Damage on Silicon Wafers Sliced Using Wire-Electrical Discharge Machining

2018 ◽  
Vol 140 (9) ◽  
Author(s):  
Kamlesh Joshi ◽  
Upendra Bhandarkar ◽  
Indradev Samajdar ◽  
Suhas S. Joshi
Keyword(s):  
Raman Spectroscopy ◽  
Electrical Discharge ◽  
Thermal Damage ◽  
Electrical Discharge Machining ◽  
Wafer Surface ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Material Loss ◽  
Pulse On Time

Slicing of Si wafers through abrasive processes generates various surface defects on wafers such as cracks and surface contaminations. Also, the processes cause a significant material loss during slicing and subsequent polishing. Recently, efforts are being made to slice very thin wafers, and at the same time understand the thermal and microstructural damage caused due to sparking during wire-electrical discharge machining (wire-EDM). Wire-EDM has shown potential for slicing ultra-thin Si wafers of thickness < 200 μm. This work, therefore, presents an extensive experimental work on characterization of the thermal damage due to sparking during wire-EDM on ultra-thin wafers. The experiments were performed using Response surface methodology (RSM)-based central composite design (CCD). The damage was mainly characterized by scanning electron microscope (SEM), transmission electron microscopy (TEM), and Raman spectroscopy. The average thickness of thermal damage on the wafers was observed to be ∼16 μm. The damage was highly influenced by exposure time of wafer surface with EDM plasma spark. Also, with an increase in diameter of plasma spark, the surface roughness was found to increase. TEM micrographs have confirmed the formation of amorphous Si along with a region of fine grained Si entrapped inside the amorphous matrix. However, there were no signs of other defects like microcracks, twin boundaries, or fracture on the surfaces. Micro-Raman spectroscopy revealed that in order to slice a wafer with minimum residual stresses and very low presence of amorphous phases, it should be sliced at the lowest value of pulse on-time and at the highest value of open voltage (OV).

Sign in / Sign up

Export Citation Format

Share Document