Micro-Forming Process and Microstructure of Deposit by Using Micro EDM Deposition in Air

2008 ◽  
Vol 375-376 ◽  
pp. 153-157 ◽  
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Bai Dong Jin
Keyword(s):  
High Speed ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
High Speed Steel ◽  
Solidification Process ◽  
Pulse Interval ◽  
Tool Electrode ◽  
Micro Edm ◽  
Forming Process ◽  
Long Pulse

Based on analysis of the mechanism of Electrical Discharge Machining (EDM) and the characteristics of deposition processing, the processing conditions of micro EDM Deposition (micro EDD) are determined. Micro EDD is a new EDM method taking air as machining medium, using narrow pulse width, long pulse interval, low discharge current and connecting the tool electrode with the anode of pulse generator. Using EDM shaping machine and brass, tungsten and steel as tool electrode respectively, micro cylinders are deposited on high-speed steel surface. And then the microstructure of deposit is analyzed detailedly. Results show that elements of the deposited material distribute uniformly, whose components depend on the tool electrode material. As the high cooling rate of the solidification process, the deposit grain size refines obviously, which leads to the hardness of tungsten or steel deposit increasing. Moreover, the Metallurgical bonding has occurred on the interface between deposit and high-speed steel base, whose thickness is about 5μm.

Technique of Brass Spiral Structure Deposition Using Micro EDM in Gas

2007 ◽  
Vol 329 ◽  
pp. 595-600
Author(s):  
Zhen Long Wang ◽  
Bai Dong Jin ◽  
Guo Hui Cao ◽  
Z.W. Wei ◽  
Wan Sheng Zhao
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Spiral Structure ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Processing Parameters ◽  
Pulse Interval ◽  
Tool Electrode ◽  
External Diameter

This paper proposes a new deposition method using micro electrical discharge machining (EDM) to deposit micro spiral structure in gas. First, the basic principles of micro electrical discharge deposition (EDD) are analyzed and the realized conditions are predicted. Then with an ordinary EDM shaping machine, brass as the electrode, high-speed steel as the workpiece, a lot of experiments are carried out on the micro spiral structure deposition in air. The effects of major processing parameters, such as the discharge current, discharge duration, pulse interval, gravity and working medium, are obtained. As a result, a 19-circle micro spiral structure with 0.19mm in external diameter, 0.1mm in wire diameter and 3.39mm in height is deposited. Measurements show that the deposited material has obvious delaminating structure, the components of which depend on those of the tool electrode material, although Zn in the electrode is oxidized to ZnO. This method establishes the research basis for micro three-dimensional deposition machining.

A Micro-Deposition Method by Using EDM

2007 ◽  
Vol 339 ◽  
pp. 32-36 ◽  
Author(s):  
Bai Dong Jin ◽  
Guo Hui Cao ◽  
Zhen Long Wang ◽  
Wan Sheng Zhao
Keyword(s):  
Electrode Material ◽  
High Speed ◽  
Steel Surface ◽  
High Speed Steel ◽  
Processing Parameters ◽  
Tool Electrode ◽  
Micro Edm ◽  
Deposition Method ◽  
Basic Principles ◽  
And Tungsten

A new micro EDM method is described. First, the basic principles of micro EDD are analyzed and realized conditions are predicted. Then with an ordinary EDM shaping machine and electrode brass, steel and tungsten, a large number of experiments are carried out in air to obtain the effects of different processing parameters on micro EDD. A micro cylinder with 0.19mm in diameter and 7.35mm in height is formed on high-speed steel surface. By exchanging the polarities of electrode and workpiece the deposited material can be removed selectively, thus the reversible machining is realized. In the end, measurements show that the deposited material is compact and hardened, whose components depend on the tool electrode material although Zn in brass electrode is oxidized to ZnO.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

A New Technology to Machine Bimetal Band Saw

2016 ◽  
Vol 861 ◽  
pp. 9-13
Author(s):  
Hong Jian Dong ◽  
Qin He Zhang ◽  
Lei Tan ◽  
Guo Wei Liu ◽  
Tuo Dang Guo
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
New Technology ◽  
High Speed Steel ◽  
Processing Route ◽  
Grinding Process ◽  
Wire Electrical Discharge Machining ◽  
Low Carbon ◽  
Band Saw

As a kind of commonly used tools, junior hacksaw plays an important role in our daily life. A new kind of bimetal band saw taken low carbon medium alloy steel X32 as the backing material and the high-speed steel M42 as the saw tooth material is developed. In this paper, a new method to machine the bimetal band saw with wire electrical discharge machining (WEDM) is introduced. The processing route for common tooth profile is calculated. The fixture with specific angles is designed with CAD software (proe5.0) and machined with 3D printing technology. The experiments show that bimetal band saw machined with WEDM method has better surface quality compared with that machined through the traditional grinding process. Without any burrs, the new bimetal band saw is more resistant to wear and has a longer service life.

Electrical Discharge Machining of Submicron-Diameter Micropins

2010 ◽  
Vol 447-448 ◽  
pp. 238-241 ◽  
Author(s):  
Hiromitsu Ueno ◽  
Yuki Kono ◽  
Kai Egashira
Keyword(s):  
Electrical Discharge ◽  
Tungsten Wire ◽  
Open Circuit Voltage ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Open Circuit ◽  
Tool Electrode ◽  
Stray Capacitance ◽  
Finish Machining ◽  
The Wire

The wire electrodischarge grinding (WEDG), which is one of the electrical discharge machining (EDM) methods, of submicron-diameter zinc micropins was attempted using a relaxation-type pulse generator. Tungsten wire of 30 µm diameter was employed as the tool electrode. The open-circuit voltage was set at lower than or equal to 15 V in the finish machining step. The electrostatic capacitance of the pulse generator was its stray capacitance only. As a result, a micropin of 0.3 µm diameter was processed. They are the smallest-diameter micropins fabricated by EDM, to the best of our knowledge.

Research on Energy-Saving EDM Pulse Power Supply

2008 ◽  
Vol 375-376 ◽  
pp. 714-718
Author(s):  
Yu Kui Wang ◽  
Bo Yan Song ◽  
Zhen Long Wang ◽  
Wan Sheng Zhao
Keyword(s):  
Energy Saving ◽  
Power Factor ◽  
Power Supply ◽  
High Speed ◽  
Closed Loop ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Pulse Power ◽  
Electrode Wear ◽  
Pulse Power Supply

The performance and stability of output of electrical discharge machining (EDM) are determined by the output of EDM pulse power supply. In order to resolve disadvantages of conventional pulse power supply, such as undesirable efficiency and low power factor, the prototype design of energy-saving EDM pulse power supply is developed. It is composed of such three stages as a single-phase active power factor correction (PFC) pre-regulator, a full-bridge phase shift zero voltage switching (FB-PS-ZVS) converter based on complex control paralleled of machining current closed-loop and voltage closed-loop at period of spark gap insulation, and a pulse generator based on machining sequence control. The PFC pre-regulator contributes to a great increase to about 0.95 in its power factor. The efficiency of the new system is considerably increased to about 70% due to design of ZVS. The pulse generator contributes to the pulse machining current without a tail. Experiment results demonstrates that the prototype is capable of low electrode wear, high speed, stable machining.

Research on Micro EDM Machine Tool for Machining Micro Array Holes

2012 ◽  
Vol 472-475 ◽  
pp. 2401-2404 ◽  
Author(s):  
Guo Zheng Zhu ◽  
Ji Cheng Bai ◽  
Yong Feng Guo ◽  
Peng Ju Hou ◽  
Chao Jiang Li
Keyword(s):  
Machine Tool ◽  
Electrical Discharge ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Micro Edm ◽  
Generator System ◽  
Micro Nozzle ◽  
Micro Electrical Discharge Machining ◽  
Micro Array ◽  
New Type

As demands for the micro array holes in modern industry and the characteristics of micro Electrical Discharge Machining (micro EDM), a new type micro EDM machine tool used to machine micro array holes was designed and manufactured. The machine tool contains following systems: the mechanism system, the control system, the pulse generator system and other auxiliary systems. Each system was studied respectively. Base on a large number of experiments, finally, a sample with 256 array holes was processed by the machine tool. The diameter of single hole is 45µm and precision of the holes is ±1µm. The sample has been successfully applied to R & D test of micro nozzle components

Micro Electrical Discharge Machining of Tungsten Carbide with Ultra-Short Pulse

2015 ◽  
Vol 651-653 ◽  
pp. 759-764
Author(s):  
Oliver Kröning ◽  
Mathias Herzig ◽  
Matthias Hackert-Oschätzchen ◽  
Ralf Kühn ◽  
Henning Zeidler ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Short Pulse ◽  
High Surface ◽  
Micro Edm ◽  
High Surface Quality ◽  
Micro Electrical Discharge Machining ◽  
Metal Machining ◽  
Ultra Short Pulse

Micro EDM (Electrical Discharge Machining) is a known nonconventional process for the machining of hard to cut materials. Due to its ablating nature based on melting and evaporation through heat induced by electrical discharges, it can function independently of the hardness, toughness or brittleness of the workpiece. Thus micro EDM is a possible process to fulfill the requirements of higher precision and high quality in carbide metal machining. Thereby the surface and the roughness of machined carbide metals depend on the discharge energy used. For machining carbide metals with high surface quality pulse generators with ultra-short discharges are required. This paper presents the development of a two-staged pulse generator with the ability to provide ultra-short pulses by using a two-staged pulse. The current and voltage signals of the discharges were recorded and their characteristics were analyzed.

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