Fabrication of Minitype Cutting Tool Based on the Electrode Dressing Technique

2012 ◽  
Vol 472-475 ◽  
pp. 2537-2541
Author(s):  
Fang Jiang ◽  
Wen Min Liao
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
High Efficiency ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
New Method ◽  
Fabrication Method ◽  
Factors Affecting ◽  
Machining Quality ◽  
Shape Precision

Based on the electrode finishing technique in electrical discharge machining (EDM), a new method is proposed in the article to fabricate minitype cutting tool efficiently. The research on the techniques to attain the minitype cutting tool was based on analyzing the feature of EDM on minitype cutter. The process of fabrication for minitype cutting tool is determined, and the minitype grooving tools with the characteristic sizes of 70 μm were made of two types of materials. This fabrication method proved to be applicable to high efficiency fabrication of minitype cutting tool. The factors affecting precision of minitype cutter were analyzed, the causes for worse shape precision and surface roughness were described specifically, and the suggestions to improve the machining quality were proposed.

Impact Analysis of Electrode Material on Electrical Discharge Machining Polycrystalline Diamond Processing

2013 ◽  
Vol 441 ◽  
pp. 36-39
Author(s):  
Yun Hai Jia
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Electrode Material ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Surface Effect ◽  
Cutting Tools ◽  
Process Conditions

The electrode material plays a very important role in the electric discharge machining, affects the electrical discharge machining efficiency and machining surface quality. Experiment testing and materials analysis as the primary method, affect layer thickness and workpiece surface roughness value as evaluation indexes. PCD cutting tool samples were electrical discharge machined using copper electrodes and graphite electrodes respectively. After machining, the PCD cutting tool samples' surfaces were analyzed by X ray diffraction, the surfaces appearances were observed under the scanning electron microscope, and the surface roughness values were measured by roughness measuring instrument. PCD samples' surface effect layer thickness values and surface roughness values, affect layer distribution structure was statically analyzed in typical EDM process conditions with different electrode materials. Summary electrode material effect on PCD cutting tools in EDM processing. Provides an important experimental basis for designing technics of precision and highly efficient electrical discharge machining PCD cutting tools.

Study on EDM Machining Technics of Polycrystalline Diamond Cutting Tool and PCD Cutting Tool’s Life

2011 ◽  
Vol 268-270 ◽  
pp. 309-315 ◽  
Author(s):  
Yun Hai Jia ◽  
Jian Gang Li ◽  
Xue Jun Lu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Machining Parameter ◽  
Diamond Cutting Tool ◽  
The Relationship

The Samples of Polycrystalline Diamond (PCD) Cutting Tool Were Machined by Adjusting the Main Parameters of Electrical Discharge Machining (EDM). after the Machining, the Phases Were Analyzed by X-Ray Diffraction Analyzer and the Surface Layer Microstructure Were Observed by Scanning Electronic Microscope. the Fundamental Component of Machined PCD Cutting Tool Affected Layer Was Obtained and the Reason of Bring Affected Layer Was Analyzed. the Relationship Curves between Pulse Width, Working Electric Current and Depth Affected Layer, Surface Roughness Were Summarized. the Relationship between PCD Cutting Tools that Was Machined by EDM and Cutting Tool Flank Width, Workpiece Surface Roughness Were Analyed.The Results Showed that to Adjust Electical Discharge Machining Parameter, such as Pulse Width and Machining Electric Currents, Can Reduce the Depth of Affect Layer and Extend the Service Life of PCD Cutting Tool.These Researches Provide Valuable Test Reference for Drawing up Electrical Discharge Machining Technics of PCD Cutting Tool and Cutting Tool’s Life.

Study on EDM Technics of Polycrystalline Cubic Boron Nitride Cutting Tool and PcBN Cutting Tool’s Life

2011 ◽  
Vol 120 ◽  
pp. 311-315 ◽  
Author(s):  
Yun Hai Jia
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cubic Boron Nitride ◽  
Blade Surface ◽  
Polycrystalline Cubic Boron Nitride ◽  
The Relationship

The samples of Polycrystalline cubic boron nitride (PcBN) cutting tool were machined by adjusting the main parameters of electrical discharge machining (EDM). After the machining, the phases were analyzed by X-ray diffraction analyzer and the surface layer microstructure was observed by scanning electronic microscope. The fundamental component of machined PcBN cutting tool affected layer was obtained and the reason of begetting affected layer was analyzed. The relationship curves between pulse width, working electric current and thickness of affected layer, blade surface roughness were summarized. The relationship between PcBN cutting tool’s life that was machined by EDM and cutting tool flank width, workpiece surface roughness were analyzed. The results showed that to adjust electrical discharge machining parameters, such as decreasing pulse width or machining electric currents, can reduce the thickness of affect layer, improve blade surface roughness and extend the service life of PcBN cutting tool. These researches provide valuable test reference for drawing up electrical discharge machining technics of PcBN cutting tool and forecasting cutting tool’s life.

Recent Patents on Micro-EDM Milling

2020 ◽  
Vol 13 (3) ◽  
pp. 219-229
Author(s):  
Baocheng Xie ◽  
Jianguo Liu ◽  
Yongqiu Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Processing Method ◽  
Electrode Wear ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Processing Methods ◽  
Machining Quality ◽  
Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

scholarly journals The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

2020 ◽  
Vol 10 (1) ◽  
pp. 401-407
Author(s):  
Yanuar Rohmat Aji Pradana ◽  
Aldi Ferara ◽  
Aminnudin Aminnudin ◽  
Wahono Wahono ◽  
Jason Shian-Ching Jang
Keyword(s):  
Surface Roughness ◽  
Metallic Glasses ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Recast Layer ◽  
Surface Evaporation ◽  
Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

2021 ◽  
pp. 095440892110414
Author(s):  
TS Senthilkumar ◽  
R Muralikannan ◽  
T Ramkumar ◽  
S Senthil Kumar
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Box Behnken Design ◽  
Pulse On Time

A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

Surface Roughness at Wire Electrical Discharge Machining

2015 ◽  
Vol 760 ◽  
pp. 551-556 ◽  
Author(s):  
Oana Dodun ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Vasile Merticaru ◽  
Gheorghe Nagîţ
Keyword(s):  
Surface Roughness ◽  
Empirical Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Wire Electrical Discharge Machining ◽  
Power Type ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining is a machining method by which parts having various contours could be detached from plate workpieces. The method uses the electrical discharges developed between the workpiece and the wire tool electrode found in an axial motion, when in the work zone a dielectric fluid is recirculated. In order to highlight the influence exerted by some input process factors on the surface roughness parameter Ra in case of a workpiece made of an alloyed steel, a factorial experiment with six independent variables at two variation levels was designed and materialized. As input factors, one used the workpiece thickness, pulse on time, pulse off-time, wire axial tensile force, current intensity average amplitude defined by setting button position and travelling wire electrode speed. By mathematical processing of the experimental results, empirical models were established. Om the base of a power type empirical model, graphical representations aiming to highlight the influence of some input factors on the surface roughness parameter Ra were achieved. The power type empirical model facilitated establishing of order of factors able to exert influence on the surface roughness parameter Ra at wire electrical discharge machining.

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