Complex Grinding Assisted with Electrical Discharge Machining for Electrically Conductive PCD

2010 ◽  
Vol 126-128 ◽  
pp. 591-596 ◽  
Author(s):  
Manabu Iwai ◽  
Shinichi Ninomiya ◽  
Gaku Sugino ◽  
Kiyoshi Suzuki
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Material Removal ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Grinding Force ◽  
Wheel Wear ◽  
Electrically Conductive ◽  
Composite Diamond

A new PCD material named EC-PCD (Electrically conductive polycrystalline composite diamond), which consists of electrically conductive diamond grits, has recently been developed. This paper deals with an investigation of a complex grinding assisted with electrical discharge machining (EDM) to realize high efficiency, low and stable grinding force and low wheel wear for the new EC-PCD. The effect of complex grinding assisted with EDM is compared experimentally with the standard PCD (S-PCD). The result shows that, in the complex grinding, lower and more stable grinding force is realized thanks to the material removal action in EDM and that lower wheel wear and better surface finish are attained, just when the EC-PCD is selected as a workpiece.

Processing EC-PCD by Constant-Force Grinding Assisted with EDM

2010 ◽  
Vol 126-128 ◽  
pp. 645-650
Author(s):  
Gaku Sugino ◽  
Manabu Iwai ◽  
Tadakazu Sano ◽  
Shinichi Ninomiya ◽  
Kiyoshi Suzuki
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Condition ◽  
Grinding Force ◽  
Constant Force ◽  
Wheel Wear ◽  
Electrically Conductive

A new PCD (electrically conductive PCD: EC-PCD) consisting of electrically conductive diamond particles has recently been developed. The authors have proposed a complex grinding assisted with electrical discharge machining (EDM) where discharge machining and grinding are used in combination during material removal to realize high efficiency, low and stable grinding force and low wheel wear for the EC-PCD. In this study, the effect of constant-force grinding in a complex grinding assisted with electrical discharge machining of EC-PCD was investigated. As a result, it was found that higher material removal rate, higher grinding ratio and better surface condition were obtained on EC-PCD compared with standard PCD (S-PCD) in the constant-force grinding.

Effect of Complex Electrodischarge Grinding for Electrically Conductive PCD

2011 ◽  
Vol 325 ◽  
pp. 276-281 ◽  
Author(s):  
Manabu Iwai ◽  
Shinichi Ninomiya ◽  
Kiyoshi Suzuki
Keyword(s):  
High Efficiency ◽  
Low Cost ◽  
Surface Condition ◽  
High Hardness ◽  
Grinding Wheel ◽  
Wheel Wear ◽  
Electrically Conductive ◽  
Grinding Method ◽  
Conventional Grinding ◽  
Composite Diamond

Polycrystalline Composite Diamond (PCD) is excellent in chipping resistance despite its very high hardness. However, it is not easy to EDM or grind PCD. To realize high efficiency and high quality processing of PCD simply and at low cost, the authors devised new PCD (EC-PCD) by using electrically conductive diamond particles and applied a complex electrodischarge grinding method. In this study, investigation is made on effective grinding condition to realize high efficiency, low and stable grinding force and low wheel wear in complex electrodischarge grinding. As a result, superior grinding property was obtained when the grinding wheel was set at minus polarity, and set peak current of iP = 4 and 6 A was applied. Furthermore it also became clear that additional conventional grinding process followed after complex electrodischarge grinding improved the surface condition.

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.

Electrically Conductive and Wear Resistant Si3N4-Based Composites with TiC0.5N0.5 Particles for Electrical Discharge Machining

2005 ◽  
Vol 492-493 ◽  
pp. 27-32 ◽  
Author(s):  
Dongtao Jiang ◽  
Jef Vleugels ◽  
Omer Van der Biest ◽  
Wei Dong Liu ◽  
Raf Verheyen ◽  
...  
Keyword(s):  
Hot Pressing ◽  
Electrical Discharge ◽  
Material Removal ◽  
Bending Strength ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Strong Anisotropy ◽  
Electrically Conductive ◽  
Wear Resistant ◽  
Lower Material

Electrically conductive and wear resistant Si3N4-based composites were developed in order to facilitate electrical discharge machining (EDM). The microstructural and mechanical properties of Si3N4-based composites with different amounts of TiC0.5N0.5, fabricated by hot pressing at 1650°C for 1 hour, are investigated and evaluated. The hardness of the micron-sized TiC0.5N0.5 powder based composites increased with increasing TiC0.5N0.5 content from 20 up to 40 vol. %, whereas the bending strength decreased. The fracture toughness reached a maximum at 30 vol. % TiC0.5N0.5 and exhibits a strong anisotropy with respect to the hot-pressing direction. The EDM behaviour of the composites is strongly influenced by the TiC0.5N0.5 content. The composites with a higher TiC0.5N0.5 content have a lower material removal rate but a better surface quality.

Current Research Trends on Dry, Near-Dry and Powder Mixed Electrical Discharge Machining

2011 ◽  
Vol 264-265 ◽  
pp. 956-961 ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M.M. Rahman ◽  
M.M. Noor ◽  
K. Kadirgama ◽  
M.A. Maleque
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Trends ◽  
Dielectric Fluid ◽  
Electrically Conductive ◽  
Conventional Machining ◽  
Edm Process ◽  
Dies And Moulds

Electrical discharge machining (EDM) technique has been widely used in modern metal working industry for producing complex cavities in dies and moulds, which are otherwise difficult to create by conventional machining. The process has the advantage of being able to machine hardened tool steels. However, its low machining efficiency and poor surface finish restricted its further applications. To address these problems, one relatively new technique used to improve the efficiency and surface finish is EDM in the presence of powder suspended in the dielectric fluid. Powder mixed electric discharge machining (PMEDM) is one of the recent innovations for the enhancement of capabilities of EDM process. In PMEDM, the electrically conductive powder is mixed in the dielectric fluid of EDM, which reduces the insulating strength of the dielectric fluid and increases the spark gap between the tool and workpiece. As a result, the process becomes more stable, thereby, improving the material removal rate (MRR) and surface finish. Moreover, the surface develops high resistance to corrosion and abrasion. This paper presents the current research trends on dry, near dry EDM and review on research carried out in the area of PMEDM.

Attempt of Electrodischarge Grinding with an Electrically Conductive Diamond-Cutting-Edge Wheel

2005 ◽  
Vol 291-292 ◽  
pp. 63-66 ◽  
Author(s):  
Kiyoshi Suzuki ◽  
Shinichi Ninomiya ◽  
Manabu Iwai ◽  
Y. Tanaka ◽  
Yoshihiko Murakami ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Diamond Wheel ◽  
Grinding Force ◽  
High Speed Camera ◽  
Discharge Condition ◽  
Diamond Cutting ◽  
Electrically Conductive ◽  
Dressing Action

Electro-discharge grinding (hereafter called ED-grinding) was carried out with a trial manufactured metal bond diamond wheel containing electrically conductive diamond grits (hereafter called EC-D-grits-wheel). In this research two effects i.e. removal action of workpiece by electrical discharge machining, and an in-process dressing action of the cutting edges on the grits are expected to take place. The results of ED-grinding with EC-D-grits-wheel (f100mm, SDE120Q80M) on tungsten carbide indicated a significant decrease of 21% in the grinding force, when the set discharge current was increased from 0A to 12A. It was also clarified from the alternative-grinding test with and without an electro-discharge action that stable grinding characteristics along with a reduced grinding force could be achieved in the case of the EC-D-grits-wheel with the electro-discharge action. High-speed camera photographs indicated that a stable discharge condition was achieved.

Machining Characteristics of Magnetic Force-Assisted Electrolytic Machining for Polycrystalline Silicon

2011 ◽  
Vol 325 ◽  
pp. 523-529
Author(s):  
Po Huai Yu ◽  
Jung Chou Hung ◽  
Hsin Min Lee ◽  
Kun Ling Wu ◽  
Biing Hwa Yan
Keyword(s):  
Electrical Discharge ◽  
Polycrystalline Silicon ◽  
Material Removal ◽  
Magnetic Force ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Electrolyte Circulation ◽  
Machining Characteristics ◽  
Temperature Melting

Wire electrical discharge machining (WEDM) of polycrystalline silicon (polysilicon) involves high-temperature melting that easily produces cracks on the silicon surface. This paper studies improvements of cracks and craters on surface of polysilicon after wire electrical discharge machining (WEDM) by magnetic force-assisted electrolytic machining (MFA-EM). The effects of different MFA-EM parameters on material removal and surface roughness are explored to understand the machining characteristics of MFA-EM and how magnetic field assistance contributes to high-efficiency and high-quality machining. Experimental results show that compared with standard EM, MFA-EM can achieve better machining efficiency and surface quality because MFA-EM can effectively enhance electrolyte circulation and replenishment, which contributes to better machining stability.

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.

Sign in / Sign up

Export Citation Format

Share Document