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.

Analysis of wire erosion and workpiece surface roughness in wire electrical discharge machining

2003 ◽  
Vol 217 (5) ◽  
pp. 633-642 ◽  
Author(s):  
N Tosun ◽  
C Cogun
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Open Circuit ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Workpiece Surface ◽  
The Wire ◽  
Dielectric Flushing ◽  
Wire Wear

In this study, the effects of machining parameters on the wire wear, on the size of erosion craters on the wire and on the workpiece surface roughness were investigated experimentally in wire electrical discharge machining (WEDM). An attempt was made to correlate the crater volume and the pulse energy. The experiments were conducted under different settings of pulse duration, open-circuit voltage, wire speed and dielectric flushing pressure. The variations of the wire wear, the size of erosion craters on the wire and the workpiece surface roughness with machining parameters were modelled mathematically by using regression analysis. The relationship between the workpiece surface roughness and the crater size was established. The analysis of variance (ANOVA) and F-test were performed to obtain statistically significant process parameters and the percentage contribution of these parameters to the performance outputs.

Optimization of the Wire Electrical Discharge Machining Process Using Grey Relational Analysis and Taguchi Method

2015 ◽  
Vol 651-653 ◽  
pp. 738-743
Author(s):  
Oana Dodun ◽  
Vasile Merticaru ◽  
Laurenţiu Slatineanu ◽  
Margareta Coteaţă
Keyword(s):  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Wire Electrical Discharge Machining ◽  
Relational Analysis ◽  
The Wire ◽  
Grey Relational

The wire electrical discharge machining is a machining method able to allow detaching parts from plates type workpieces as a consequence of electrical discharges developed between workpiece and wire tool electrode found in a motion along its axis; there is also a work motion along the contour to be obtained. There are many factors able to exert influence on the sizes of parameters of technological interest. On the other hand, there are various methods that can be used in order to establish the optimal combination of the input factors, so that obtaining of machining best results is possible. When there are many process output factors, a problem of multiobjective optimization could be formulated. The Grey relational analysis method and the Taguchi method could be applied in order to optimize the wire electrical discharge machining process, when various criteria having distinct significances are considered. An experimental research was designed and developed in order to optimize the wire electrical discharge cutting of parts made of an alloyed steel, by considering six input factors: test piece thickness, pulse on time, pulse off time, wire axial tensile, current intensity and travelling wire electrode speed. As output parameters, one took into consideration surface roughness, wire tool electrode massic wear, cutting speed along the contour to be obtained. 16 experiments were developed in accordance with the requirements specific to a Taguchi table L16. The results of experiments were processed by means of Grey relational analysis method and Taguchi method.

Device for Wire Electrical Discharge Machining

2014 ◽  
Vol 657 ◽  
pp. 569-573
Author(s):  
Gheorghe Bosoancă ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Ana Bădănac ◽  
Vasile Manole
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Tool Electrode ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrical Discharge Machine ◽  
Machining Processes ◽  
Discharge Machine ◽  
The Wire ◽  
The Given

The problem approached in this paper refers to designing a device for wire electrical discharge machining (EDM) which can be used on a ram electrical discharge machine. Usually, wire electrical discharge machine is applied only on specialized electrical discharge machines. The device proposed in the paper will ensure widening the technological possibilities of the given ram EDM equipment. A principle schema of the device was established, after analyzing the main requirements specific to the device service. One took into consideration a possibility to rotate and fix the subassembly for guiding the wire electrode so that the active zone of the wire tool electrode has a horizontal, vertical or even inclined position. Another requirement was to ensure a way for achieving machining processes in cavities existing in workpieces of higher dimensions. Functioning of the designed device and strain resistance of some components were tested by using CATIA V5 software. Some optimization possibilities for this constructive solution of the device were identified.

Automatic Stripping of Dielectric-Encased Wire Tool Electrode Used in Electrical Discharge Machining

2007 ◽  
Vol 129 (5) ◽  
pp. 973-978
Author(s):  
Seiji Kumagai ◽  
Naoki Sato ◽  
Koichi Takeda
Keyword(s):  
Control System ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Threshold Value ◽  
Electrode System ◽  
Tool Electrode ◽  
Feed Speed ◽  
Wire Electrode ◽  
Aspect Ratios ◽  
The Wire

A new electrical discharge machining (EDM) system using a wire encased in a dielectric jacket is proposed as an alternative to conventional hole-fabrication EDM systems. The jacket suppresses secondary discharges occurring between the sidewalls of the wire and the fabricated hole, which allows fabrication of holes with higher aspect ratios compared to those formed by a conventional EDM system using naked pipe electrodes. In this new system, the tip of the wire electrode is stripped by displacing the jacket, which produces continuous sparks for workpiece erosion and keeps the bore and shape of the fabricated holes constant. In the present study, we developed a control system to maintain the exposed length of the tip without the need for visual observation and without the assumption that wear is constant over time. The exposed length of the tip of the wire electrode is related to the feed speed (toward the workpiece) of the electrode system. The jacket was displaced when the feed speed of the electrode system exceeded a threshold value, which resulted in slowing of the electrode system feed. The feed speed was kept within the specified range by determining a threshold value, which led to maintenance of a constant exposed length of the tip. This control system was validated in actual drilling tests. Optimizing the threshold feed speed contributed to a higher machining speed.

scholarly journals Sub-Microstructure of Surface and Subsurface Layers after Electrical Discharge Machining Structural Materials in Water

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1040
Author(s):  
Sergey N. Grigoriev ◽  
Marina A. Volosova ◽  
Anna A. Okunkova ◽  
Sergey V. Fedorov ◽  
Khaled Hamdy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Structural Materials ◽  
12Kh18n10t Steel ◽  
Mean Deviation ◽  
Water Medium ◽  
Tool Electrode ◽  
Marquardt Algorithm ◽  
Subsurface Layers ◽  
Electrical Wear

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researched. The machining was conducted using a brass tool of 0.25 mm in diameter. The measured discharge gap is 45–60 µm for X10CrNiTi18-10 (12kH18N10T) steel and 105–120 µm for 2024 (D16) duralumin. Surface roughness parameters are arithmetic mean deviation (Ra) of 4.61 µm, 10-point height (Rz) of 28.73 µm, maximum peak-to-valley height (Rtm) of 29.50 µm, mean spacing between peaks (Sm) of 18.0 µm for steel; Ra of 5.41 µm, Rz of 35.29 µm, Rtm of 43.17 µm, Sm of 30.0 µm for duralumin. The recast layer with adsorbed components of the wire tool electrode and carbides was observed up to the depth of 4–6 µm for steel and 2.5–4 µm for duralumin. The Levenberg–Marquardt algorithm was used to mathematically interpolate the dependence of the interelectrode gap on the electrical resistance of the material. The observed microstructures provide grounding on the nature of electrical wear and nanomodification of the obtained surfaces.

scholarly journals Influence of Energy Parameters of Micro WEDM on Kerf

2012 ◽  
Vol 576 ◽  
pp. 527-530
Author(s):  
Mohammad Yeakub Ali ◽  
W.Y.H. Liew ◽  
S.A. Gure ◽  
B. Asfana
Keyword(s):  
Experimental Data ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Wire Electrode ◽  
Wire Vibration ◽  
The Wire ◽  
Micro Wedm

This paper presents the estimation of kerf width in micro wire electrical discharge machining (micro WEDM) in terms of machining parameters of capacitance and gap voltage. An empirical model is developed by the analysis of variance (ANOVA) of experimental data. Using a wire electrode of 70 µm diameter, a minimum kerf width is found to be 92 µm for the micro WEDM parameters of 0.01 µF capacitance and 90.25 V gap voltage. Around 30% increament of the kerf is found to be high. The analysis also revealed that the capacitance is more influential parameter than gap voltage on kerf width produced by micro WEDM. As the gap voltage determines the breakdown distance and affects the wire vibration, the wire vibration factor is to be considered in the analysis and in formulation of model in future study.

Effect of Arc Discharge Pressure on Discharge Current in EDM

2008 ◽  
Vol 381-382 ◽  
pp. 451-454
Author(s):  
Atsutoshi Hirao ◽  
S. Tai ◽  
H. Takezawa ◽  
Naotake Mohri ◽  
Kazuro Kageyama ◽  
...  
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Vibration Sensor ◽  
Work Piece ◽  
Tool Electrode ◽  
Discharge Pressure ◽  
Current Behavior

In electrical discharge machining (EDM), an electrical discharge occurs between a tool electrode and a work-piece, and removal of materials is carried out by vaporized explosion between the electrode and the work-piece. However, the mechanism of material removal in EDM is not well understood. In order to clarify this issue, the acoustic emission (AE) method has been applied to examine the force of explosion, and the Schlieren visualization method has been applied to observe the explosion. In this study, we investigate the effect of discharge current behavior on the occurrence of the AE waves by means of an optical fiber vibration sensor.

scholarly journals Wire Electrical Discharge Machining—A Review

Machines ◽  
2020 ◽  
Vol 8 (4) ◽  
pp. 69
Author(s):  
Laurenţiu Slătineanu ◽  
Oana Dodun ◽  
Margareta Coteaţă ◽  
Gheorghe Nagîţ ◽  
Irina Beşliu Băncescu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrode ◽  
Machining Processes ◽  
Scientific Papers ◽  
The Wire ◽  
Machining Productivity ◽  
Machined Surfaces

Wire electrical discharge machining has appeared mainly in response to the need for detachment with sufficiently high accuracy of parts of plate-type workpieces. The improvements introduced later allowed the extension of this machining technology to obtain more complex ruled surfaces with increasingly high requirements regarding the quality of the machined surfaces and the productivity of the wire electrical discharge machining process. Therefore, it was normal for researchers to be interested in developing more and more in-depth investigations into the various aspects of wire electrical discharge machining. These studies focused first on improving the machining equipment, wire electrodes, and the devices used to position the clamping of a wire electrode and workpiece. A second objective pursued was determining the most suitable conditions for developing the machining process for certain proper situations. As output parameters, the machining productivity, the accuracy, and roughness of the machined surfaces, the wear of the wire electrode, and the changes generated in the surface layer obtained by machining were taken into account. There is a large number of scientific papers that have addressed issues related to wire electrical discharge machining. The authors aimed to reveal the aspects that characterize the process, phenomena, performances, and evolution trends specific to the wire electrical discharge machining processes, as they result from scientific works published mainly in the last two decades.

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