Precision Control of Kerf in Metal Cutting Using Dry Micro WEDM: Issues and Challenges

2018 ◽  
Vol 775 ◽  
pp. 499-505 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Asfana Banu ◽  
Mohamed Abdul Rahman ◽  
Muataz Hazza Faizi Al Hazza ◽  
Erry Yulian Triblas Adesta
Keyword(s):  
Mathematical Models ◽  
Stable Process ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
High Dimensional ◽  
Dielectric Fluid ◽  
Wire Edm ◽  
Micro Wedm ◽  
Micro Tools ◽  
Edm Process

Micro dry wire EDM is a process where gas is used as the dielectric fluid instead of a liquid. In this process certain modifications of a wire EDM are needed during the machining operation to achieve stable machining. Optimizing kerf to get high dimensional accuracy is one of the critical issues in micro dry wire EDM. The fundamental modelling for optimum kerf using micro dry wire EDM has not been formulated yet. Due to the complex phenomenon, the prediction of optimum kerf in a micro dry wire EDM process is rather difficult. Hence, the main objectives of this research are to improve the micro dry wire EDM process and to develop mathematical models for optimum kerf using micro dry wire EDM. During the process improvement of micro dry wire EDM, various machining setup will be involve in order to achieve the most stable process. The most stable machining process will be used to prove the developed mathematical models. A mathematical relationship between kerf and process parameters is anticipated. The mathematical models in conjunction with experimental data will eventually produce the desired theory. The developed process and mathematical model of kerf is a breakthrough in fabricating products such as micro tools, molds etc. with optimum kerf and high dimensional accuracy. The successful completion of this research will contribute to the environmental friendly micromachining process.

scholarly journals Metal Machining—Recent Advances, Applications, and Challenges

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 580
Author(s):  
Francisco J. G. Silva
Keyword(s):  
Surface Finish ◽  
Manufacturing Process ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
High Dimensional ◽  
Manufacturing Processes ◽  
Recent Advances ◽  
Metal Machining ◽  
Rapid Manufacture

Though new manufacturing processes that revolutionize the landscape regarding the rapid manufacture of parts have recently emerged, the machining process remains alive and up-to-date in this context, always presenting itself as a manufacturing process with several variants and allowing for high dimensional accuracy and high levels of surface finish [...]

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

scholarly journals Electrical Discharge Machining: Vital to Manufacturing Industries

2019 ◽  
Vol 8 (11) ◽  
pp. 1696-1701 ◽  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Manufacturing Industries ◽  
Potential Difference ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Conventional Process ◽  
Edm Process ◽  
State Of Art ◽  
Process Material

This paper presents an insight of state of art of electrical discharge machining process. In this process, material gets eroded from the workpiece because of chain of speedily repeating current discharges amidst twin electrodes, which are parted by dielectric fluid and made prone to a potential difference. This process offers various advantages over conventional process and finds wide applications in various industries. The information provided in this study will be very useful for the beginners to understand the basic fundamentals of unconventional EDM process

Wire Electrical Discharge Machining (Wire EDM) Cutting of Flexures for a Rotary Flexural Bearing Fabrication

2011 ◽  
Vol 314-316 ◽  
pp. 1727-1733
Author(s):  
Hong Ping Luo ◽  
Zhi Xiong Zhou ◽  
Yong Jun Zhang ◽  
Zhong Ning Guo
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Torsional Stiffness ◽  
Wire Electrical Discharge Machining ◽  
Wire Edm ◽  
Factors Affecting ◽  
Before And After ◽  
Cutting Sequence

Wire electrical discharge machining (Wire EDM) cutting of flexures for a rotary flexural bearing fabrication is developed. The results of FEA calculation and theoretical analysis show that one of the main factors affecting flexures’ machining is the weak torsional stiffness of the bearing cage, thus excessive deflections due to machining stress, heat generation and spark-induced vibrations may occur. To minimize flexure deflection during the machining process, a specially designed fixture is utilized. Other technical measures, including residual stress relief before and after Wire EDM cutting, reasonable cutting sequence planning, multiple-cutting (i.e., rough cut followed by several trim cuts) etc., are also adopted for cutting. Dimensional accuracy of ±5µm was obtained over the 150µm thickness for the bearing flexures, a variation of less than 3µm was achieved for the flexures of opposing sides, and surface roughness of better than Ra 0.3μm was obtained for the flexures of the entire bearing cage. These results show the validity of measures aforementioned.

Performance Analysis of Vegetable Oil as Dielectric Fluid in Electric Discharge Machining Process of Inconel 800

2020 ◽  
Vol 978 ◽  
pp. 77-83
Author(s):  
Balasubramaniyan Singaravel ◽  
K.Chandra Shekar ◽  
G.Gowtham Reddy ◽  
S. Deva Prasad
Keyword(s):  
Dielectric Properties ◽  
Vegetable Oil ◽  
Vegetable Oils ◽  
Electric Discharge ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Electric Discharge Machining ◽  
Dielectric Fluids ◽  
Edm Process ◽  
Inconel 800

Electric discharge machining (EDM) is a spark erosion process widely used to machine difficult-to-cut material by conventional machining method. The major elements of EDM process are work piece, electrode and dielectric fluid. In this work, an attempt is made to investigate vegetable oil as dielectric fluid and their process performance for machining of Inconel 800 in EDM process. The effects of dielectric fluids are investigated with vegetable oils and conventional dielectric fluid namely Sunflower oil and Kerosene respectively. The important input variables considered in this study are pulse on/off time, current and voltage. Three levels of energy setting are employed for machining with selected dielectric fluids. The output parameters are considered tool wear rate (TWR), material removal rate (MRR) and surface roughness (SR). In the present study effect of vegetable oil as dielectric fluid and the results are compared with conventional dielectric fluid. The result revealed that vegetable oils are successfully employed as dielectric fluids and they are having similar dielectric properties and erosion mechanism compared to conventional dielectric fluid. This proposed vegetable oil based dielectric fluids showed higher MRR than conventional dielectric. It shows vegetable oils have similar dielectric properties compared with conventional dielectric and it is possible to replace as dielectric fluid in EDM process.

scholarly journals Dual-axial Ultrasonic Assisted Wire-EDM Process with Vibration Exerted through the Upper Guide

Procedia CIRP ◽  
2020 ◽  
Vol 95 ◽  
pp. 319-324
Author(s):  
Albert Wen-Jeng Hsue ◽  
Zih-Siou Su ◽  
Yang-Lei Lin
Keyword(s):  
Wire Edm ◽  
Ultrasonic Assisted ◽  
Edm Process

Novel die-sinking micro-electro discharge machining process using microelectromechanical systems technology

2006 ◽  
Vol 220 (9) ◽  
pp. 1481-1487 ◽  
Author(s):  
J-B Li ◽  
K Jiang ◽  
G J Davies
Keyword(s):  
Microelectromechanical Systems ◽  
Machining Process ◽  
Metallic Surface ◽  
Manufacturing Cost ◽  
Sem Images ◽  
Deep Reactive Ion Etching ◽  
Electro Discharge Machining ◽  
Mems Technology ◽  
Fabrication Condition ◽  
Edm Process

A novel die-sinking micro-electro discharge machining (EDM) process is presented for volume fabrication of metallic microcomponents. In the process, a high-precision silicon electrode is fabricated using deep reactive ion etching (DRIE) process of microelectromechanical systems (MEMS) technology and then coated with a thin layer of copper to increase the conductivity. The metalized Si electrode is used in the EDM process to manufacture metallic microcomponents by imprinting the electrode onto a flat metallic surface. The two main advantages of this process are that it enables the fabrication of metallic microdevices and reduces manufacturing cost and time. The development of the new EDM process is described. A silicon component was produced using the Surface Technology Systems plasma etcher and the DRIE process. Such components can be manufactured with a precision in nanometres. The minimum feature of the component is 50 μm. In the experiments, the Si component was coated with copper and then used as the electrode on an EDM machine of 1 μm resolution. In the manufacturing process, 130 V and 0.2 A currents were used for a period of 5 min. The SEM images of the resulting device show clear etched areas, and the electric discharge wave chart indicates a good fabrication condition. The experimental results have been analysed and the new micro-EDM process is found to be able to fabricate 25 μm features.

Multi-Response Optimization of Wire-EDM Process Parameters of Titanium Alloy Using Taguchi Method and Grey Relational Analysis

2015 ◽  
Vol 772 ◽  
pp. 245-249
Author(s):  
A. Ramamurthy ◽  
R. Sivaramakrishnan ◽  
S. Venugopal ◽  
T. Muthuramalingam
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Wire Edm ◽  
Relational Analysis ◽  
Response Optimization ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

It is very important and complexity to find the optimum values of wire EDM process parameters and contribution of each parameter to attain the better performance characteristics. In this study, an attempt has been made to optimize those parameters while machining the titanium alloy. Since the process involves more one than one response parameter, it is essential to carry out the multi-response optimization methodology .The experiments have been conducted with different levels of input factors such as pulse on time,pulse off time and wire tension based on Taguchi L9 orthogonal table.Wire EDM optimal process parameter has been identified using grey relational analysis and significant parameter has been determined by analysis of variance. Experimental results have indicated that the multi-response characteristic such as material removal rate and surface roughness can be improved effectively through grey relational analysis.

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