Material Removal in WEDM of PCD Blanks

1994 ◽  
Vol 116 (3) ◽  
pp. 363-369 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
S. Z. Wang
Keyword(s):  
Material Removal ◽  
Thermal Stresses ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Advanced Materials ◽  
The Matrix ◽  
Diamond Grain ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are now widely used in machining a large variety of advanced materials. However, the manufacture of PCD tool blanks is not an economical and efficient process. The shaping of PCD blanks with conventional machining methods (such as grinding), is a long, labor-intensive and costly process. Wire electric discharge machining (WEDM) promises to be an effective and economical technique for the production of tools from PCD blanks. However, a knowledge base for wire electrical discharge machining of PCD blanks needs comprehensive investigations into the proper parameter setting, metal removal mechanisms, and surface integrity of machined blanks. This paper presents the results of experimental and theoretical investigations of the influence of discharge frequency and discharge energy on the material removal rate of WEDM of PCD blanks. The mechanism of removing diamond grains from the matrix during electrical erosion is also discussed on the basis of thermal stresses between the diamond grain and cobalt phase.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

Optimization of Cutting Conditions of YG15 on Finish Cutting in WEDM Based on Taguchi Method

2014 ◽  
Vol 887-888 ◽  
pp. 1195-1199
Author(s):  
Zhi Chen ◽  
Zhen Zhang ◽  
Wu Yi Ming ◽  
Hao Huang
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Performance ◽  
Finish Cutting ◽  
Cutting Operation

Wire electrical discharge machining (WEDM) is extensively used in the mold, instrument and manufacturing industries, and rough cutting operation in WEDM is treated as a challenging process because improvement of more than one machining performance measures viz. metal removal rate (MRR), roughness (Ra) are sought to obtain a precision work. In this paper, first of all, a set of Taguchi experiment (L18 21×34) is carried out based on the Taguchi method. Secondly, two groups of ANOM are completed to obtain the influence trends of each parameters on material removal rate (MRR) and roughness (Ra), respectively. Eventually, three groups of best process parameters combination are acquired to meet high material removal rate (MRR) and low roughness (Ra) simultaneously, it can provide guiding significance to actual machining process.

Modeling of Active Gap Capacitance Electrical Discharge Machining

2020 ◽  
pp. 1-12
Author(s):  
Xiangzhi Wang ◽  
Hun Guo ◽  
Jiyuan Tu ◽  
Songlin Ding
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Electrode Wear ◽  
Discharge Process ◽  
Mixed Effect ◽  
Capacitive Effect

Abstract Active gap capacitance electrical discharge machining (AGC-EDM) is a high-speed EDM method for machining polycrystalline diamond tools utilizing the active capacitive effect and powder mixing effect formed by the kerosene dielectric added with graphene particles. The capacitive effect increases the discharge energy and explosive force, which in turn influences the material removal efficiency; the powder mixed effect changes the states of dielectric and forms a non-fixed gap discharge process. Take into account these two aspects, a new discharge mechanism of AGC-EDM is proposed to describe the discharge process. Capacitance characteristics and chain stacking process of graphene-kerosene dielectrics are verified by experimental results. The material removal rate, relative electrode wear and surface roughness are discussed with the pulse duration, peak current, and graphene concentration to study the theories of the new EDM process.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

scholarly journals Electric Discharge Grinding of Polycrystalline Diamond Materials

2012 ◽  
Vol 271-272 ◽  
pp. 333-337 ◽  
Author(s):  
Song Lin Ding ◽  
John P.T. Mo ◽  
Milan Brandt ◽  
Richard Webb
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Working Condition ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Optimal Parameters ◽  
Power Generator ◽  
The Poor ◽  
Edm Process ◽  
Selection Of

The poor electric conductivity of polycrystalline diamond (PCD) makes it difficult to machine with the conventional EDM process. Inappropriate selection of parameters of the power generator and the servo system leads to unstable working condition and low material removal rate. This paper introduces a method to find optimal parameters in the Electrical Discharge Grinding (EDG) of PCD materials with Taguchi method. The theory and detailed procedures are presented, experimental results are analyzed. The optimized configuration was validated through confirmation tests.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

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.

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