Development of Small Radius Ball End Mill for Deep Precision Machining - Feasibility of Highly Accurate Deep Precision Machining with Less Vibration -

2007 ◽  
Vol 329 ◽  
pp. 583-588
Author(s):  
Takeshi Akamatsu ◽  
Koichi Kitajima ◽  
Y. Matsumoto ◽  
T. Kiriyama
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Systematic Investigation ◽  
Small Radius ◽  
Precision Machining ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
End Mill ◽  
End Mills

The machining of metal dies involves a variety of processes that include grinding, polishing and electrical discharge machining in addition to various cutting processes such as turning, boring, and milling. The precise machining of complex dies, particularly in deep machining, has largely been done by electrical discharge machining in the past, because the use of end mills and other cutting tools for such work has been difficult. In recent years, however, problems such as low machining efficiency and the creation of an affected layer have made the use of end mill cutting tools the general approach to this task. In the research reported here, our objective was to establish guidelines for the optimum design of small radius ball end mills for the deep machining of dies by systematic investigation of the cutting tool characteristics, which is to say the rotational behavior, cutting resistance, actual rate of depth of cut and machining accuracy of small radius ball end mills. Here, the guidelines obtained for ultra-deep, highly-accurate machining that is applicable to machining programs and is based on quantitative results for amounts of tool wear and tool deflection that obtained using the optimum tool shape reported earlier are presented.

Influence of Material of Small Radius Ball End Mill on Cutting Accuracy in Deep Precision Machining

2005 ◽  
Vol 291-292 ◽  
pp. 471-474 ◽  
Author(s):  
Takeshi Akamatsu ◽  
Koichi Kitajima ◽  
S. Minamino ◽  
T. Kiriyama
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Coating Material ◽  
Small Radius ◽  
Precision Machining ◽  
End Mill ◽  
Ball End Mill ◽  
Form Accuracy ◽  
Edge Profile ◽  
Die And Mold

Machining of complex shape and deep micro cavity in die and mold is mostly carried out by electrical discharge machining process. However, it may not be able to sufficiently meet delivery deadline minimization and cost reduction of die and mold. Therefore, precision machining method using small radius ball end mill capable of machining deep cavities in miniature die and mold is proposed as a substitute for electrical discharge machining. This report presents such a result supported by experiment in which it has been proved that long tool life of ball end mill can be maintained by changing coating material and edge profile of small radius ball end mill experiencing form accuracy and get needed surface finish in workpiece. Therefore, for precision machining of die and mold as substitute for electrical discharge machining, it is proposed to perform deep precision machining using small radius ball end mill. This paper shows effect proved by experiment how cutting characteristics which occur by changing of coating material and edge profile of small radius ball end mill influence form accuracy and finishing surface of workpiece.

Fabrication of Micropins Using Micro Turning Tools

2012 ◽  
Vol 523-524 ◽  
pp. 76-80 ◽  
Author(s):  
Takuya Furukawa ◽  
Yosuke Nomura ◽  
Kazuyuki Harada ◽  
Kai Egashira
Keyword(s):  
Tungsten Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Tool Breakage ◽  
Micro Cutting ◽  
Hard Materials ◽  
Micro Turning

The turning of straight micropins with a diameter smaller than 10 µm, which has not been reported so far, was carried out using micro turning tools made of cemented tungsten carbide. Tools of 50 µm diameter were fabricated by electrical discharge machining, which is suitable for fabricating micro cutting tools because it can deal with hard materials and carry out micromachining. A turning machine designed especially for micro turning tools was used in the experiments. A brass workpiece was turned using a tool with a length of cut of 100 µm at a feed speed of 3.0 µm/s, feed per revolution of 0.06 µm and depth of cut of 10–11 µm. As a result, a straight micropin of 7.5 µm diameter and 80 µm length was successfully turned. Furthermore, turning was also performed using a tool with a length of cut of 50 µm at a feed speed of 3.0 µm/s, feed per revolution of 0.06 µm and depth of cut of 8.5–20 µm to fabricate a straight micropin of 3 µm diameter and 30 µm length. This micropin is the pin with the smallest ever diameter fabricated by turning, to the best of our knowledge, indicating the possibility of further minimization of the machinable size in turning. Turning properties were also investigated to determine the maximum depth of cut and feed speed that can be employed without tool breakage.

scholarly journals Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

Coatings ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 590
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
Tomas Prokes ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Cutting Speed ◽  
Machining Process ◽  
Precision Machining ◽  
Machining Accuracy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Super Alloy ◽  
Machined Surfaces

Wire electrical discharge machining (WEDM) is an unconventional and very efficient technology for precision machining of the Nimonic C 263 super alloy, which is very widespread, especially in the energy, aerospace and automotive industries. Due to electrical discharge, defects in the form of cracks or burned cavities often occur on the machined surfaces, which negatively affect the correct functionality and service life of the manufactured components. To increase the efficiency of the machining of Nimonic C 263 using WEDM, in this study, extensive design of experiments was carried out, monitoring input factors in the form of machine parameters like Pulse off time, Gap voltage, Discharge current, Pulse on time and Wire feed, the output of which was comprehensive information about the behaviour of such machined surfaces, which allowed the optimization of the entire machining process. Thus, the optimization of the Cutting speed was performed in relation to the quality of the machined surface and the machining accuracy, as well as an analysis of the chemical composition of the machined surfaces and a detailed analysis of the lamella using a transmission electron microscope. A detailed study of the occurrence of surface or subsurface defects was also included. It was found that with the help of complex optimization tools, it is possible to significantly increase the efficiency of the machining of the Nimonic C 263 super alloy and achieve both financial savings in the form of shortened machine time and increasing the quality of machined surfaces.

Study on Modeling and Simulation of Wire Vibration in WEDM

2012 ◽  
Vol 472-475 ◽  
pp. 2013-2017
Author(s):  
Chao Jiang Li ◽  
Yong Feng Guo ◽  
Ji Cheng Bai ◽  
Ze Sheng Lu ◽  
Chuan Chen
Keyword(s):  
Electrical Discharge ◽  
Pulse Width ◽  
Metal Cutting ◽  
Electrical Discharge Machining ◽  
Orthogonal Design ◽  
Pulse Interval ◽  
Machining Accuracy ◽  
Wire Tension ◽  
Wire Vibration ◽  
The Wire

The wire electrical discharge machining (WEDM) has been widely used in the field of metal cutting, mold industry, aerospace and so on. However, in the discharge machining, it is very important to restrain the wire-tool vibration for the improvement of machining accuracy. In this paper, it is created a model of the wire vibration with double-ended fixed, established the differential equation of vibration, and derived its full theoretical solution to analysis the vibration factors. Simulations of the wire vibration with ANSYS Transient dynamics analysis were given. An orthogonal design of the wire vibration using L9 orthogonal table was made, and the experiment found that minimize the servo voltage, reduce the pulse width, and select the appropriate wire tension and pulse interval, which can reduce the wire vibration.

The Predictive Model of Surface Roughness and Searching System in Database for Cutting Tool Grinding

2009 ◽  
Vol 626-627 ◽  
pp. 11-16 ◽  
Author(s):  
Yung Cheng Wang ◽  
Chen Hsiang Chen ◽  
Bean Yin Lee
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Rapid Development ◽  
Cutting Tools ◽  
Experiment Planning ◽  
Grinding Wheel ◽  
End Mill ◽  
Grinding Parameters ◽  
End Mills ◽  
Tool Grinding

Due to the rapid development in recent cutting technology, demands for different types of precise cutting tools become increasingly complicated. Since the design and grinding of end-mills are the last and the most important processing for cutting tools. The geometrical accuracy and the cutting performance of an end-mill depend essentially on the grinding. However, the complicated geometry of an end-mill will be ground by the specific software of CAD/CAM on the 5-axis CNC tool grinding machine. The precision of end-mill grinder will be determined by the performance of 5-axis CNC tool grinder and setting of grinding parameters. Three regulation factors for grinding are grit size of the diamond grinding wheel, grinding speed and the feeding speed. The variable ranges of each parameter can be divided in large, medium and small interval. In this study for an end-mill with fixed geometrical profile, a series of different grinding parameters have been utilized by the 33 factorial experiment planning. And tool grinding experiments for the rod material specification of tungsten carbide have been performed by 5-axis CNC tool grinder. After grinding, surface roughness of tools will be measured. The reliability and precision of the end-mill grinding can be enhanced by the prediction model of polynomial network for surface roughness of end-mills. Besides, the database system for cutting tool has benn established. Totally 4802 data were constructed in the relational database according to the characteristics of tools.

scholarly journals The accuracy of machining during electro-discharge cutting process using different-diameter electrodes

Mechanik ◽  
2017 ◽  
Vol 90 (11) ◽  
pp. 1000-1002 ◽  
Author(s):  
Jan Burek ◽  
Robert Babiarz ◽  
Jarosław Buk ◽  
Marcin Płodzień ◽  
Paweł Sułkowicz
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Aircraft Engine ◽  
Cutting Process ◽  
Machining Accuracy ◽  
Wire Electrical Discharge Machining ◽  
Heat Resistant Alloy ◽  
Resistant Alloy ◽  
Different Diameters

The WEDM (wire electrical discharge machining) accuracy tests were performed. Electrodes of different diameters were used to cut the blade lock profile of an aircraft engine made from the heat-resistant alloy Inconel 718.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

Analysis of the electrical discharge machining (EDM) performance on Ramor 550 armor steel

2020 ◽  
Vol 62 (5) ◽  
pp. 481-491
Author(s):  
Engin Nas
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Processing Parameters ◽  
Depth Of Cut ◽  
Armor Steel ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Abstract This study investigated the electrical discharge machining (EDM) performance of Ramor 500 Armor steel, a material used in the defense industry for armor production. In addition, the surface quality and amount of material wear of the treated surfaces were determined using different electrical discharge processing parameters for a copper electrode including pulse on-time (99, 150, 225, 300, 351 μs), pulse off-time (10, 15, 23, 30, 35 μs), and discharge current (3, 4, 6, 8, 9 A), at a constant pressure of 1 mm depth of cut. As a result of the experiments, the values related to the material removal rate (MRR) and the surface roughness (Ra) were obtained and the findings analyzed via response surface methodology (RSM). The increase in amperage and pulse on time resulted in an increase in Ra and MRR values. The minimum and maximum Ra and MRR values emerged at currents of 3 and 9 A, respectively. In the experiments performed applying currents of between 3 and 9 A, the white layer widths were measured as 0.0474 mm and 0.0915 mm, respectively. The statistical test results showed that the most effective processing parameters for the MRR were the discharge current amperage (49.01 %) and the pulse off-time (16.51 %), whereas the most effective parameter for the Ra value was the discharge current amperage (79.07 %).

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