Journal ArticleDOI
Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 1: Concept, Design, and Material Removal Rate
Reads0
Chats0
TLDR
In this article, the design of a precise, flexible, and corrosion-resistant underwater rotary spindle has been introduced to generate cylindrical forms on hard, difficult-to-machine materials.Abstract:
Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of a precise, flexible, and corrosion-resistant underwater rotary spindle is first introduced. A detailed spindle error analysis identifies the major sources of error at different frequency spectrum. The spindle has been added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometries. The mathematical model for material removal rate of the free-form cylindrical wire EDM process is derived. Experiments were conducted to explore the maximum material removal rate for cylindrical and 2D wire EDM of carbide and brass work-materials. Compared to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates may be achieved in the cylindrical wire EDM, possibly due to better debris flushing condition.read more
Citations
More filters
Journal ArticleDOI
State of the art in wire electrical discharge machining (wedm)
TL;DR: In this paper, the authors reviewed the vast array of research work carried out from the spin-off from the EDM process to the development of the WEDM, and highlighted the adaptive monitoring and control of the process investigating the feasibility of different control strategies of obtaining the optimal machining conditions.
Journal ArticleDOI
Modelling the machining parameters of wire electrical discharge machining of Inconel 601 using RSM
TL;DR: In this paper, the authors highlight the development of mathematical models for correlating the interrelationships of various WEDM machining parameters of Inconel 601 material such as: peak current, duty factor, wire tension and water pressure on the metal removal rate, wear ratio and surface roughness.
Journal ArticleDOI
Multi response optimization of wire EDM operations using robust design of experiments
R. Ramakrishnan,L. Karunamoorthy +1 more
TL;DR: In this paper, a multi response optimization method using Taguchi's robust design approach is proposed for wire electrical discharge machining (WEDM) operations, where the machining parameters are optimized with the multi response characteristics of the material removal rate, surface roughness, and wire wear ratio.
Journal ArticleDOI
Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 2: Surface Integrity and Roundness
TL;DR: In this paper, a mathematical model for the arithmetic average surface roughness on the ideal surface of a cylindrical wire EDM workpiece is derived and the effects of wire feed rate and part rotational speed on the surface finish and roundness for brass and carbide work-materials at high material removal rates are investigated.
Journal ArticleDOI
Statistical analysis of wire electrical discharge turning on material removal rate
TL;DR: In this paper, a rotary spindle was mounted on a wire electrical discharge machining (WEDM) machine to rotate the workpiece in order to generate free form cylindrical geometries.
References
More filters
Journal ArticleDOI
Micro-EDM for Three-Dimensional Cavities - Development of Uniform Wear Method -
TL;DR: In this article, a uniform wear method for 3D micro-EDM was proposed, which maintains the original electrode shape and converts the three dimensional electrode wear to a linear one.
Journal ArticleDOI
Three-Dimensional Micromachining by Machine Tools
TL;DR: In this article, the state-of-the-art machining technologies for three-dimensional microproducts are summarized by focusing on the methods using tools, and promising methods for machining convex and concave shapes are introduced and discussed with respect to their state of the art.
Journal ArticleDOI
3D Micro-EDM Using CAD/CAM
Kamlakar P Rajurkar,Zuyuan Yu +1 more
TL;DR: In this article, a CAD/CAM system was integrated with micro-EDM to generate 3D micro-cavities using a recently developed uniform wear method, and the feasibility of the approach is illustrated by generating complex macro cavities using conventional EDM with single simple shaped electrodes.
Journal ArticleDOI
A Combined Electrical Machining Process for Micronozzle Fabrication
TL;DR: In this paper, a combined process with EDM, ECM and electroforming was proposed for the production of precision nozzles with small diameters and various inner shapes, which were successfully produced with good concentricity to the outer profile.
Journal ArticleDOI
Micro ultrasonic machining and its applications in MEMS
TL;DR: In this paper, a combined machining method, micro ultrasonic machining (micro-USM), is proposed for the fabrication of three-dimensional (3D) microstructures with high aspect ratios.