High Spindle Speed Wire Electrical Discharge Grinding Using Electrostatic Induction Feeding Method

2010 ◽  
Vol 447-448 ◽  
pp. 268-271 ◽  
Author(s):  
Yuna Yahagi ◽  
Tomohiro Koyano ◽  
Masanori Kunieda ◽  
Xiao Dong Yang
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Rotation Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Workpiece Surface ◽  
Feeding Method ◽  
Electrostatic Induction ◽  
Micro Holes ◽  
Machining Characteristics

This paper describes machining characteristics of high spindle speed WEDG using the electrostatic induction feeding method. In this method, non-contact electric feeding allows the workpiece rod to be rotated at a high speed of up to 50000rpm. Since the temperature rise on the workpiece surface is low, the material removal rate was two times higher and the surface roughness was also improved compared to the normal RC discharge circuit where the rotational speed was 1000rpm at the highest due to contact electric feeding using a brush. Furthermore, micro rods thus prepared were used as tool electrodes to machine micro-holes with the same rotation speed of 50000rpm. It was found that smaller gaps and better straightness can be obtained due to the high flushing efficiency at the high spindle speed.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Influences of Varying Combination of Feed Rate and Depth of Cut to Tool Wear Rate and Surface Roughness: High Speed Machining Technique in Non-High Speed Milling Machine

2014 ◽  
Vol 903 ◽  
pp. 194-199
Author(s):  
Mohd Zairulnizam Zawawi ◽  
Mohd Ali Hanafiah Shaharudin ◽  
Ahmad Rosli Abdul Manaf
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Tool Wear Rate

Machining technique using high spindle speed, high feed rate and shallow depth of cut utilize in High Speed Milling (HSM) machines offer several benefits such as increase of productivity, elimination of secondary and semi-finishing process, reduce tool load and small chips produced. By adjusting some of the machining parameters, non-HSM machine having lower spindle speed and feed rate could also take advantages some of the benefits mentioned above when applying the HSM technique. This experiment investigate the effects of varying combination of depth of cut and feed rate to tool wear rate and surface roughness during end milling of Aluminum and P20 tool steel in dry condition. The criterion for tool wear before it gets rejected is based on maximum flank wear, Vb of 0.6mm. Material removal rate, spindle speed and radial depth of cut are constant in this experiment. After preliminary machining trials, the combination starts with depth of cut of 2mm and feed rate of 45mm/min until the smallest depth of cut and highest feed rate of 0.03mm and 3000mm/min respectively. The obtained result shows that for both materials, feed rate significantly influences the surface roughness value while depth of cut does not as the surface roughness value keep increasing with the increase of feed rate and decreasing depth of cut. Whereas, tool wear rate almost remain unchanged indicates that material removal rate strongly contribute the wear rate. With no significant tool wear rate, this study demonstrates that HSM technique is possible to be applied in non-HSM machine with extra benefits of eliminating semi-finishing operation, reducing tool load for finishing, machining without coolant and producing smaller chip for ease of cleaning.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

EDM with USM Combination Process of Sintered NdFeB Permanent Magnet

2010 ◽  
Vol 44-47 ◽  
pp. 1066-1069
Author(s):  
Li Li ◽  
Li Ling Qi ◽  
Zong Wei Niu
Keyword(s):  
Permanent Magnet ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Dielectric Fluid ◽  
Machined Surface ◽  
Combination Process ◽  
Electro Discharge Machining ◽  
Ndfeb Permanent Magnet ◽  
Machining Characteristics

This paper presents an experimental investigation of the machining characteristics of sintered NdFeB permanent magnet using a combination process of electro-discharge machining (EDM) with ultrasonic machining (USM). Concentration of abrasive in the dielectric fluid is changed to explore its effect on the material removal rate (MRR). MRR of EDM /USM, conventional EDM are compared, machined surface characteristics are also compared between them. It is concluded that the combination EDM/USM process can increase the MRR and decrease the thickness of the recast layer. In the combination process, an appropriate abrasive concentration can improve its machining efficiency.

Parametric Study of Micro Machining Three Dimensional Microstructure with the Tiny-Grinding Wheel Based on the EMR Effect

2010 ◽  
Vol 447-448 ◽  
pp. 193-197
Author(s):  
Wei Qiang Gao ◽  
Qiu Sheng Yan ◽  
Yi Liu ◽  
Jia Bin Lu ◽  
Ling Ye Kong
Keyword(s):  
Magnetic Field ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Machining Time ◽  
Fluctuation Phenomenon

Electro-magneto-rheological (EMR) fluids, which exhibit Newtonian behavior in the absence of a magnetic field, are abruptly transformed within milliseconds into a Bingham plastic under an applied magnetic field, called the EMR effect. Based on this effect, the particle-dispersed EMR fluid is used as a special instantaneous bond to cohere abrasive particles and magnetic particles together so as to form a dynamical, flexible tiny-grinding wheel to machine micro-groove on the surface of optical glass. Experiments were conducted to reveal the effects of process parameters, such as the feed rate of the horizontal worktable, feeding of the Z axis, machining time and machining gap, on material removal rate of glass. The results indicate that the feed rate of the worktable at horizontal direction has less effect on material removal rate, which shows a fluctuation phenomenon within a certain range. The feed rate of the Z axis directly influences the machining gap and leads to a remarkable change on material removal rate. Larger material removal rate can be obtained when the feeding frequency of Z direction is one time per processing. With the increase of rotation speed of the tool, material removal rate increases firstly and decreases afterwards, and it gets the maximum value with the rotation speed of 4800 rev/min. The machining time is directly proportional to material removal amount, but inversely proportional to material removal rate. Furthermore, material removal rate decreases with the increase of the machining gap between the tool and the workpiece. On the basis of above, the machining mode with the tiny-grinding wheel based on the EMR effect is presented.

Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

scholarly journals Performance Evaluation and Comparison between Direct and Chemical-Assisted Picosecond Laser Micro-Trepanning of Single Crystalline Silicon

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 41 ◽  
Author(s):  
Hao Zhu ◽  
Zhaoyang Zhang ◽  
Kun Xu ◽  
Jinlei Xu ◽  
Shuaijie Zhu ◽  
...  
Keyword(s):  
Material Removal ◽  
Crystalline Silicon ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Orthogonal Experimental Design ◽  
Single Crystalline Silicon ◽  
Machining Performance ◽  
Single Crystalline ◽  
Direct Laser ◽  
Micro Holes

The fabrication of micro-holes in silicon substrates that have a proper taper, higher depth-to-diameter ratio, and better surface quality has been attracting intense interest for a long time due to its importance in the semiconductor and MEMS (Micro-Electro-Mechanical System) industry. In this paper, an experimental investigation of the machining performance of the direct and chemical-assisted picosecond laser trepanning of single crystalline silicon is conducted, with a view to assess the two machining methods. The relevant parameters affecting the trepanning process are considered, employing the orthogonal experimental design scheme. It is found that the direct laser trepanning results are associated with evident thermal defects, while the chemical-assisted method is capable of machining micro-holes with negligible thermal damage. Range analysis is then carried out, and the effects of the processing parameters on the hole characteristics are amply discussed to obtain the recommended parameters. Finally, the material removal mechanisms that are involved in the two machining methods are adequately analyzed. For the chemical-assisted trepanning case, the enhanced material removal rate may be attributed to the serious mechanical effects caused by the liquid-confined plasma and cavitation bubbles, and the chemical etching effect provided by NaOH solution.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

INVESTIGATION OF SINGLE-POINT DRESSING OVERLAP RATIO AND DIAMOND-ROLL DRESSING INTERFERENCE ANGLE ON SURFACE ROUGHNESS IN GRINDING

2010 ◽  
Vol 34 (2) ◽  
pp. 295-308 ◽  
Author(s):  
Akram Saad ◽  
Robert Bauer ◽  
Andrew Warkentin
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Empirical Model ◽  
Material Removal ◽  
Removal Rate ◽  
Single Point ◽  
Experimental Conditions ◽  
Workpiece Surface ◽  
Different Depths ◽  
Overlap Ratio

This paper investigates the effect of both single-point and diamond-roll dressing techniques on the workpiece surface roughness in grinding. Two empirical surface roughness models are studied – one that incorporates single-point dressing parameters, and another that incorporates diamond-roll dressing parameters. For the experimental conditions used in this research, the corresponding empirical model coefficients are found to have a linear relationship with the inverse of the overlap ratio for single-point dressing and the interference angle for diamond-roll dressing. The resulting workpiece surface roughness models are then experimentally validated for different depths of cut, workpiece speeds and dressing conditions. In addition, the models are used to derive a relationship between overlap ratio for single-point dressing, and interference angle for diamond-roll dressing such that both dressing techniques produce a similar surface finish for a given material removal rate.

scholarly journals Significance of tungsten disulfide on the mechanical and machining characteristics of phosphor bronze metal matrix composite

2020 ◽  
Vol 29 ◽  
pp. 2633366X2096249 ◽  
Author(s):  
P Sangaravadivel ◽  
G Rajamurugan ◽  
Prabu Krishnasamy
Keyword(s):  
Flexural Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
High Speed ◽  
Spindle Speed ◽  
Tungsten Disulfide ◽  
Pbmc Sample ◽  
High Speed Turning ◽  
Machining Characteristics

The phosphor bronze (PB) is widely preferred in various engineering applications due to its high strength, toughness, fine grain size, low coefficient of friction, and better corrosion resistance. The present work is to investigate the effect of tungsten disulfide (WS2) solid lubricant particle reinforcement in the phosphor bronze metal matrix composite (PBMC) through the mechanical and machining characteristics. The different variant of the composite is fabricated using stir casting technique by varying the volume percentage of WS2 particle from 0% to10%. The prepared PBMC samples are subjected to mechanical and machining (boring and high-speed turning) characterizations. The hardness (Brinell hardness) and flexural strength of the composites are examined as per the ASTM standard. The surface roughness (Ra) of the PBMC sample is analyzed through the boring and high-speed turning operations by varying the spindle speed, feed rate, and depth of cut. The scanning electron microscope (SEM) is employed to confirm the uniform dispersion of the reinforcement particle through the microstructural analysis. The presence of WS2 particles and other ingredients is ensured by X-ray diffraction analysis in the composites. The influence of WS2 reinforcement particles on tool life is analyzed on the PBMC4 (PBMC with 8% WS2) with the predefined machining parameters in the high-speed turning operation. The increase in WS2 particle (0–10%) improves the hardness (11.85%) and flexural strength in PBMC4 as compared to PBMC1 (PBMC with 0% WS2). At a higher spindle speed (1200 r/min), the Ra is reduced in PBMC1 as compared to 900 r/min, whereas the rest of the PBMC sample show higher surface irregularity at 1200 r/min.

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