High-performance wire electrodes for wire electrical-discharge machining – a review:
20 Sep 2012-Vol. 226, Iss: 11, pp 1757-1773
TL;DR: In a wire electrical discharge machining process, an electrically conductive workpiece is eroded ahead of a continuous moving wire by spark discharges, which are identical with those in conventional...
Abstract: In a wire electrical-discharge machining process an electrically conductive workpiece is eroded ahead of a continuous moving wire by spark discharges, which are identical with those in conventional...
Citations
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TL;DR: In this paper, the evolution of wire electrical discharge machining (WEDM) electrode technologies from using copper to brass wire electrodes and from brass wire electrode to the latest coated wire electrodes is discussed.
Abstract: Wire electrical discharge machining (WEDM) is an important technology, which demands high-speed cutting and high-precision machining to realize productivity and improved accuracy for manufacturing hard materials. WEDM has experienced explosive growth and complexity of equipment as well as rising demand for the basic process tool (the wire electrode). Greater taper angles, thicker workpieces, automatic wire threading, and long periods of unattended operation make the selection of the ideal wire a much more critical basis for achieving successful operation. This paper focuses on the evolution of EDM wire electrode technologies from using copper to the widely employed brass wire electrodes and from brass wire electrodes to the latest coated wire electrodes. Wire electrodes have been developed to help user demand and needs through maximum productivity and quantity by choosing the best wire. In the final part of the paper, the possible trends for future WEDM electrode research are discussed.
102 citations
Cites background or methods from "High-performance wire electrodes fo..."
...High-performance wire electrodes with high conductivity alloy materials for high-speed cutting applications will be extensively used for automobile parts and die manufacturing in the future [11]....
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...4 Higher cutting rate machines using thick wires [11] 332 Int J Adv Manuf Technol (2015) 76:329–351...
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...Figure 4 illustrates the increase in wire diameter with the developed wire electrode for WEDM process improvement [42, 11]....
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...cutting speed due to increased zinc concentration and wire electrodes made of brass with added titanium and aluminum for improved heat resistance when cutting thick materials [11, 12]....
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TL;DR: In this paper, a multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization of wire electric discharge machining (WEDM) characteristics of TiNi SMA.
69 citations
01 Jun 2014
TL;DR: In this paper, the mechanism of electrical discharge machining has been combined with the mechanisms of one or more other machining/physical/chemical processes to constitute the hybrid machining process.
Abstract: Electrical discharge machining is one of the widely used noncontact-type advanced machining processes in which material removal takes place due to melting and vaporization by thermal energy of electric sparks. Electrical discharge machining has the capability of machining difficult-to-cut materials such as superalloys, advanced ceramics, and composites with complex shapes at both macro- and micro-levels. But its application is limited to electrically conductive materials. Other limitations include low material removal rate, high tool wear rate, recast layer formation, and geometrical inaccuracy in the form of taper and overcut. To overcome such limitations, the mechanism of electrical discharge machining has been combined with the mechanism of one or more other machining/physical/chemical processes. The mechanism of two constituent processes may be applied simultaneously or sequentially to constitute the hybrid machining process. It has been found that the performance of hybrid machining processes is bett...
66 citations
Cites methods from "High-performance wire electrodes fo..."
...This process is used to create complex shapes especially in difficult-to-cut materials.(5) In disk cutting EDM, a rotating or stationary disk is fed toward the workpiece and the material is removed by melting and vaporization....
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TL;DR: In this article, a comparative study of brass and molybdenum wires in the wire electrical discharge machining (WEDM) process study on surface roughness and material removal rate (MRR) performance of titanium alloy is presented.
Abstract: This research work presents the comparative usage of brass and molybdenum wires in the Wire electrical discharge machining (WEDM) process study on surface roughness and material removal rate (MRR) performance of titanium alloy. The optimum parameters of the model such as pulse current, pulse on-time and pulse off-time have been determined through L9 orthogonal array of Taguchi design of experiment methodology. Wear rate of brass wire is found to increase with rise in input energy in machining titanium alloy than in the case of molybdenum wire. The experimental analysis showed that the combination of higher levels of pulse current is essential to achieve simultaneous maximisation of MRR and minimisation of surface roughness by using Grey relational analysis coupled with principal component analysis. The surface roughness topography has been described by performing scanning electron microscope study. The WEDM machined surface revealed that craters are found on the machined surface of titanium alloy ...
34 citations
Cites background from "High-performance wire electrodes fo..."
...Kapoor, Singh, and Khamba (2012) described the wire electrical-discharge machining process using an electrically conductive workpiece which was eroded ahead of a continuous moving wire by spark discharges, which were identical to those in conventional electricaldischarge machining....
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TL;DR: In this article, the analysis and modelling of dimensional accuracy in dry micro wire electrical discharge machining with control parameters of gap voltage and wire tension was performed on stainless steel using integrated multi-process micro machine with compressed air as the dielectric fluid and tungsten as the wire electrode.
Abstract: Dimensional accuracy is important in fabricating miniaturized product in order to reduce the
material waste and machining cost as well as to achieve a better quality product. This paper
presents the analysis and modelling of dimensional accuracy in dry micro wire electrical
discharge machining with control parameters of gap voltage and wire tension. The
investigation was performed on stainless steel using integrated multi-process micro machine
tools DT 110 with compressed air as the dielectric fluid and tungsten as the wire electrode.
The dimensional accuracy was determined through kerf width differences of the machined
slots. The kerf width was measured using scanning electron microscope. Full factorial was
used to design the experiment while analysis of variance (ANOVA) was used to analyse the
results as well as to evaluate the adequacy of the developed model. Based on ANOVA, both
parameters; gap voltage and wire tension have high influence on kerf width differences. The
optimum machining parameters for minimum kerf width differences were found to be 85 V
gap voltage and 10 % wire tension. The developed model is adequate since the percentage
error (2.13 %) is relatively small. It is recommended that different type of gases should be
used for further investigation in order to determine the accuracy of the dry micro wire EDM.
26 citations
Cites methods from "High-performance wire electrodes fo..."
...Tungsten wire with 70 μm was used as the tool electrode since it has high tensile strength and load-carrying capability [35]....
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References
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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.
Abstract: Wire electrical discharge machining (WEDM) is a specialised thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilising the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Over the years, the WEDM process has remained as a competitive and economical machining option fulfilling the demanding machining requirements imposed by the short product development cycles and the growing cost pressures. However, the risk of wire breakage and bending has undermined the full potential of the process drastically reducing the efficiency and accuracy of the WEDM operation. A significant amount of research has explored the different methodologies of achieving the ultimate WEDM goals of optimising the numerous process parameters analytically with the total elimination of the wire breakages thereby also improving the overall machining reliability. This paper reviews the vast array of research work carried out from the spin-off from the EDM process to the development of the WEDM. It reports on the WEDM research involving the optimisation of the process parameters surveying the influence of the various factors affecting the machining performance and productivity. The paper also highlights the adaptive monitoring and control of the process investigating the feasibility of the different control strategies of obtaining the optimal machining conditions. A wide range of WEDM industrial applications are reported together with the development of the hybrid machining processes. The final part of the paper discusses these developments and outlines the possible trends for future WEDM research.
658 citations
"High-performance wire electrodes fo..." refers background in this paper
...Coatings on already-used copper, brass, steel and molybdenum wires by a layer of material possessing a small work function, such as magnesium, alkaline metals and alkaline earth metals, significantly increases the cutting efficiency.(92) Kapoor et al....
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TL;DR: In this article, a metal plate or metal mesh is arranged on the surface of a ceramic insulator as an assisting electrode to keep electrical conductivity on the work piece during the machining.
159 citations
TL;DR: In this article, the surface characteristics of the wire-electro discharge machining process were studied and it was observed that more uniform surface characteristics are obtained with coated wire electrode. But the most sensitive parameter was the time between two pulses.
132 citations