Showing papers on "Electrical discharge machining published in 2008"

Processing and properties of ultra-high temperature ceramics for space applications

Abstract: The processing and the properties of two ultra-high temperature ceramics (UHTCs) designed for the manufacturing of aerospace sharp-shaped hot-structures are presented, along with the results obtained in the electrical discharge machining (EDM) of these UHTCs into sharp hot-structure components. The powder mixtures in the (ZrB2–SiC)-based systems were brought to full density by hot-pressing. The hot-pressed bodies were characterized by fine and uniform microstructures (typical grain size Beyond basic mechanical properties, the machinability of UHTC blocks into a more complex shape by means of the EDM was also assessed. Sharp-shaped hot-structures in the form of a nose-cone were produced from 12 cm × 10 cm hot-pressed cylindrical blocks. The machined surfaces showed limited roughness Ra

Experimental Study of the Dry and Near-Dry Electrical Discharge Milling Processes

Abstract: This study investigates the dry and near-dry electrical discharge machining (EDM) milling to achieve a high material removal rate (MRR) and fine surface finish for roughing and finishing operations, respectively. Dry EDM uses gas and near-dry EDM applies a liquid-gas mixture as the dielectric medium. Experimental studies leading to the selection of oxygen gas and copper electrode for high MRR dry EDM and the nitrogen-water mixture and graphite electrode for fine surface finish near-dry EDM are presented. Near-dry EDM exhibits the advantage of good machining stability and surface finish under low discharge energy input. A 2 5-1 fractional factorial design is applied to investigate the effect of discharge current, pulse duration, and pulse interval on the MRR and surface finish in dry and near-dry EDMs. Lower pulse duration and lower discharge current are identified as key factors for improving the surface finish in near-dry EDM.

Modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic.

Abstract: Electric discharge machining (EDM) has achieved remarkable success in the manufacture of conductive ceramic materials for the modern metal industry. Mathematical models are proposed for the modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic which are developed using the response surface methodology (RSM) to explain the influences of four machining parameters (the discharge current, pulse on time, duty factor and open discharge voltage) on the performance characteristics of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The experiment plan adopts the centered central composite design (CCD). The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). This study highlights the development of mathematical models for investigating the influences of machining parameters on performance characteristics and the proposed mathematical models in this study have proven to fit and predict values of performance characteristics close to those readings recorded experimentally with a 95% confidence interval. Results show that the main two significant factors on the value of the material removal rate (MRR) are the discharge current and the duty factor. The discharge current and the pulse on time also have statistical significance on both the value of the electrode wear ratio (EWR) and the surface roughness (SR).

Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric (PMD-EDM)

Abstract: The addition of powder particles to the electrical discharge machining (EDM) dielectric fluid modifies some process variables and creates the conditions to achieve a higher surface quality in large machined areas. This paper presents a new research work that aims to study the improvement in the polishing performance of conventional EDM when used with a powder-mixed-dielectric (PMD-EDM). The analysis was carried out varying the silicon powder concentration and the flushing flow rate over a set of different processing areas and the effects in the final surface were evaluated. The evaluation was done by surface morphologic analysis and measured through some quality surface indicators. The results show the positive influence of the silicon powder in the reduction of crater dimensions, white-layer thickness and surface roughness. Moreover, it was demonstrated that an accurate control of the powder concentration and flushing flow is a requirement for achieving an improvement in the process polishing capability.

Artificial neural network models for the prediction of surface roughness in electrical discharge machining

Abstract: In the present paper Artificial Neural Networks (ANNs) models are proposed for the prediction of surface roughness in Electrical Discharge Machining (EDM). For this purpose two well-known programs, namely Matlab® with associated toolboxes, as well as Netlab®, were emplo- yed. Training of the models was performed with data from an extensive series of EDM experiments on steel grades; the proposed models use the pulse current, the pulse duration, and the processed material as input parameters. The reported results indicate that the proposed ANNs models can satisfactorily predict the surface roughness in EDM. Moreover, they can be considered as valuable tools for the process planning for EDMachining.

Study of vibration-assisted micro-EDM-The effect of vibration on machining time and stability of discharge

Abstract: In micro-EDM (electric discharge machining), due to the improper flushing out of the debris, frequent adhesion between a tool electrode and a workpiece prevents the continuation of the machining. Thus, a long time is required for machining, even when the machining is possible. In order to solve this problem, we introduced vibration-assisted machining to micro-EDM using PZT in an attempt to flush out debris from the gap between a tool electrode and workpiece. The results indicate that vibration assistance improves the machining stability and results in an extreme reduction of the machining time. In this study, we describe the effects of vibration-assisted micro-EDM on machining time for a range of amplitudes and frequencies. We next show the results of the discharge current and displacement of the machine table in machining, in order to prove that the machining instability comes from the adhesion between a tool electrode and a workpiece. In addition, we also showed a close relation between the stiffness of the workpiece and the adhesion phenomenon. To validate our experimental results, a small square shaft was successfully fabricated by vibration-assisted micro-EDM.

Machining characteristics of magnetic force-assisted EDM

Abstract: The gap conditions of electrical discharge machining (EDM) would significantly affect the stability of machining progress. Thus, the machining performance would be improved by expelling debris from the machining gap fast and easily. In this investigation, magnetic force was added to a conventional EDM machine to form a novel process of magnetic force-assisted EDM. The beneficial effects of this process were evaluated. The main machining parameters such as peak current and pulse duration were chosen to determine the effects on the machining characteristics in terms of material removal rate (MRR), electrode wear rate (EWR), and surface roughness. The surface integrity was also explored by a scanning electron microscope (SEM) to evaluate the effects of the magnetic force-assisted EDM. As the experimental results suggested that the magnetic force-assisted EDM facilitated the process stability. Moreover, a pertinent EDM process with high efficiency and high quality of machined surface could be accomplished to satisfy modern industrial applications.

Optimization of electrical discharge machining characteristics of WC/Co composites using non-dominated sorting genetic algorithm (NSGA-II)

Abstract: Electrical discharge machining (EDM) is a process for shaping hard metals and forming deep and complex shaped holes by arc erosion in all types of electro conductive materials. In the present work, the effectiveness of the EDM process with tungsten carbide and cobalt composites is evaluated in terms of the material removal rate and the surface finish quality of the workpiece produced. The objective of this research is to study the influence of operating parameters of EDM such as pulse current, pulse on time, electrode rotation and flushing pressure on material removal rate and surface roughness. The experimental results are used to develop the statistical models based on second order polynomial equations for the different process characteristics. The non-dominated sorting genetic algorithm (NSGA-II) has been used to optimize the processing conditions. A non-dominated solution set has been obtained and reported.

Soft computing models based prediction of cutting speed and surface roughness in wire electro-discharge machining of tungsten carbide cobalt composite

Abstract: In the present study, a second order multi-variable regression model and a feed-forward back-propagation neural network (BPNN) model have been developed to correlate the input process parameters, such as pulse on-time, pulse off-time, peak current, and capacitance with the performance measures namely, cutting speed and surface roughness while wire electro-discharge machining (WEDM) of tungsten carbide-cobalt (WC-Co) composite material. From a large number of neural network architectures, 4-11-2 has been found to be the optimal one, which can predict cutting speed and surface roughness with 3.29% overall mean prediction error. The multivariable regression model yields an overall mean prediction error of 6.02%. Both the models have been used to study the effect of input parameters on the cutting speed and surface roughness, and finally to corroborate them with those of the experimental results. Scanning electron micrographs reveal that at higher energy level the machined surface is characterized by several microcracks and loosely bound solidified WC grains.

Neural-network-based modeling and optimization of the electro-discharge machining process

Abstract: In this research, a new integrated neural-network-based approach is presented for the prediction and optimal selection of process parameters in die sinking electro-discharge machining (EDM) with a flat electrode (planing mode). A 3–6–4–2-size back-propagation neural network is developed to establish the process model. The current (I), period of pulses (T), and source voltage (V) are selected as network inputs. The material removal rate (MRR) and surface roughness (Ra) are the output parameters of the model. Experimental data were used for training and testing the network. The results indicate that the neural model can predict process performance with reasonable accuracy, under varying machining conditions. The effects of variations of the input machining parameters on process performance are then investigated and analyzed through the network model. Having established the process model, a second network, which parallelizes the augmented Lagrange multiplier (ALM) algorithm, determines the corresponding optimum machining conditions by maximizing the MRR subject to appropriate operating and prescribed Ra constraints. The optimization procedure is carried out in each level of the machining regimes, such as finishing (Ra≤2 μm), semi-finishing (Ra≤4.5 μm), and roughing (Ra≤7 μm), from which, the optimal machining parameter settings are obtained. The optimization results have also been discussed, verified experimentally, and the amounts of relative errors calculated. The errors are all in acceptable ranges, which, again, confirm the feasibility and effectiveness of the adopted approach.

Electrical Discharge Machining (EDM) Characteristics Associated with Electrical Discharge Energy on Machining of Cemented Tungsten Carbide

Abstract: In this investigation, cemented tungsten carbides graded K10 and P10 were machined by electrical discharge machining (EDM) using an electrolytic copper electrode. The machining parameters of EDM were varied to explore the effects of electrical discharge energy on the machining characteristics, such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness. Moreover, the effects of the electrical discharge energy on heat-affected layers, surface cracks and machining debris were also determined. The experimental results show that the MRR increased with the density of the electrical discharge energy; the EWR and diameter of the machining debris were also related to the density of the electrical discharge energy. When the amount of electrical discharge energy was set to a high level, serious surface cracks on the machined surface of the cemented tungsten carbides caused by EDM were evident.

A Study on Process Parameters of Ultrasonic Assisted Micro EDM Based on Taguchi Method

Abstract: Experimental investigation of ultrasonic assisted micro electro discharge machining was performed by introducing ultrasonic vibration to workpiece. The Taguchi experimental design has been applied to investigate the optimal combinations of process parameters to maximize the material removal rate and minimize the tool wear. Analysis of variance (ANOVA) was performed and signal-to-noise (S/N) ratio was determined to know the level of importance of the machining parameters. Based on ANOVA, ultrasonic vibration at 60% of the peak power with capacitance of 3300 PF was found to be significant for best MRR. The machining time plays a significant role in the tool wear. The results were confirmed experimentally at 95% confidence interval.

Effect of ultrasonic vibration of tool on electrical discharge machining of cemented tungsten carbide (WC-Co)

Abstract: This paper deals with the effect of copper tool vibration with ultrasonic (US) frequency on the electrical discharge machining (EDM) characteristics of cemented tungsten carbide (WC-Co). It was found that ultrasonic vibration of the tool (USVT) was more effective in attaining a high material removal rate (MRR) when working under low discharge currents and low pulse times (finishing regimes). In general, the surface roughness and the tool wear ratio (TWR) were increased when ultrasonic vibration was employed. It was observed that application of ultrasonic vibration significantly reduced arcing and open circuit pulses, and the stability of the process had a remarkable improvement. This study showed that, there were optimum conditions for ultrasonic assisted machining of cemented tungsten carbide, although the conditions may vary by giving other input parameters for those which had been set constant in the present work.

Development of a cutting tool condition monitoring system for high speed turning operation by vibration and strain analysis

Abstract: Cutting tool wear is a critical phenomenon which influences the quality of the machined part. In this paper, an attempt has been made to create artificial flank wear using the electrical discharge machining (EDM) process to emulate the actual or real flank wear. The tests were conducted using coated carbide inserts, with and without wear on EN-8 steel, and the acquired data were used to develop artificial neural networks model. Empirical models have been developed using analysis of variance (ANOVA). In order to analyze the response of the system, experiments were carried out for various cutting speeds, depths of cut and feed rates. To increase the confidence limit and reliability of the experimental data, full factorial experimental design (135 experiments) has been carried out. Vibration and strain data during the cutting process are recorded using two accelerometers and one strain gauge bridge. Power spectral analysis was carried out to test the level of significance through regression analysis. Experimental results were analyzed with respect to various depths of cut, feed rates and cutting speeds.

A new approach to surface roughness and roundness improvement in wire electrical discharge turning based on statistical analyses

Abstract: In this paper, the effects and the optimization of machining parameters on surface roughness and roundness in the turning wire electrical discharge machining (TWEDM) process are investigated. In the TWEDM process, a new machining parameter, such as rotational speed, is introduced, which changes the normal machining conditions in conventional wire electrical discharge machining (WEDM). By the Taguchi method, a complete realization of the process parameters and their effects were achieved. The Taguchi method has not been used in TWEDM by other researchers. The surface roughness and roundness were measured to verify the process. In addition, the open-circuit voltage, pulse-off time, open arc voltage, and the inter-electrode gap size, which are replaced by power, time-off, voltage, and servo, respectively, and also wire tension, wire speed, and rotational speed were chosen for evaluation by the Taguchi method. An L18 (21 × 37) Taguchi standard orthogonal array was chosen for the design of experiments. The level of importance of the machining parameters on the surface roughness and roundness was determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratios. The variation of surface roughness and roundness with machining parameters was mathematically modeled by using the regression analysis method. Finally, experimentation was carried out to identify the effectiveness of the proposed method. The presented model is also verified by a set of verification tests.

The drilling of Al2O3 using a pulsed DC supply with a rotary abrasive electrode by the electrochemical discharge process

Abstract: The electrochemical discharge machining (ECDM) process has the potential to machine electrically non-conductive high-strength, high-temperature-resistant (HSHTR) ceramics, such as aluminum oxide (Al2O3). However, the conventional tool configurations and machining parameters show that the volume of material removed decreases with increasing machining depth and, finally, restricts the machining after a certain depth. To overcome this problem and to increase the volume of material removed during drilling operations on Al2O3, two different types of tool configurations, i.e., a spring-fed cylindrical hollow brass tool as a stationary electrode and a spring-fed cylindrical abrasive tool as a rotary electrode, were considered. The volume of material removed by each electrode was assessed under the influence of three parameters, namely, pulsed DC supply voltage, duty factor, and electrolyte conductivity, each at five different levels. The results revealed that the machining ability of the abrasive rotary electrode was better than the hollow stationary electrode, as it would enhance the cutting ability due to the presence of abrasive grains during machining.

Modeling and Analysis of Machinability Evaluation in the Wire Electrical Discharge Machining (WEDM) Process of Aluminum Oxide-Based Ceramic

Abstract: The wire electrical discharge machining (WEDM) allowed success in the manufacture of the hard, fragile, and materials difficult to cut, especially for electroconductive ceramic materials. In this study, the mathematical models of material removal rate (MRR) and surface roughness (SR) used for the machinability evaluation in the WEDM process of aluminum oxide-based ceramic material (Al2O3 + TiC) have been carried out. The experimental plan adopts the face centered central composite design (CCD). The mathematical models using the response surface methodology (RSM) are developed so as to investigate the influences of four machining parameters, including the peak current, pulse on time, duty factor, and wire speed, on the performance characteristics of MRR and SR. It has been proved that the proposed mathematical models in this study would fit and predict values of the performance characteristics, which would be close to the readings recorded in experiment with a 95% confidence level. The significant paramete...

Influence of process parameters on electric discharge machining of WC/30%Co composites:

Abstract: Tungsten carbide/cobalt (WC/Co) cemented carbide is one of the important composite materials that are used in the manufacture of cutting tools, dies, and other special tools. It has high ha...