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Journal articles on the topic 'Wire cut EDM'

Author: Grafiati

Published: 4 June 2021

Last updated: 1 February 2022

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1

Sen, Ruma, P. Charkraborti, and J. Debbarma. "Wear Behavior in Wire of Wire Cut EDM." Applied Mechanics and Materials 704 (December 2014): 70–76. http://dx.doi.org/10.4028/www.scientific.net/amm.704.70.

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Wire electrical discharge machining (WEDM) is a specialized thermal machining process, capable of accurately machining parts with different hardness, complex shapes and sharp edges that are very difficult to be machined by the traditional machining processes. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted noncontact technique of material removal.In this paper, the effects of various process parameters of WEDM like pulse on time (Ton), peak current (IP), wire feed (WF) and wire tension (WT) have been investigated to study their impact on wear of wire of ELECTRONICA SPRINTCUT WEDM machine.It is found that the wear is influenced with increase in pulse on time (Ton) and wire tension.

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2

Takayama, Yushi, Yushinori Makino, Yan Niu, and Hiroyuki Uchida. "The Latest Technology of Wire-cut EDM." Procedia CIRP 42 (2016): 623–26. http://dx.doi.org/10.1016/j.procir.2016.02.259.

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3

SAKAI, Shigenori, and Takahisa MASUZAWA. "ECM second cut for finishing the surface produced by wire EDM." Journal of the Japan Society of Precision Engineering 51, no. 3 (1985): 609–13. http://dx.doi.org/10.2493/jjspe1933.51.609.

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4

Kinoshita, N., M. Fukui, and T. Fujii. "Study on Wire-EDM: Accuracy in Taper-Cut." CIRP Annals 36, no. 1 (1987): 119–22. http://dx.doi.org/10.1016/s0007-8506(07)62567-0.

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5

Beltrami, Ivano, Axel Bertholds, and Dirk Dauw. "A simplified post process for wire cut EDM." Journal of Materials Processing Technology 58, no. 4 (April 1996): 385–89. http://dx.doi.org/10.1016/0924-0136(95)02212-0.

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6

Liang, Jui-Fang, and Y. S. Liao. "Methods to Measure Wire Deflection in Wire EDM Machining." International Journal of Automation Technology 8, no. 3 (May 5, 2014): 461–67. http://dx.doi.org/10.20965/ijat.2014.p0461.

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It is well kown that the wire electrode is flexible and will lead to a big lag in wire EDM machining, especially in the middle area of the work-piece. Methods to measure the wire deflection when it passes through the work-piece are studied in this paper. It is found that there is discharge spark first at the upper and lower parts of the wire when it cuts to the edge of the work-piece. The discharge spark appears at the middle of the work-piece a few seconds later. Based on this result, a method coined Camera Picture Analysis (CPA) is proposed to estimate the wire deflection. Another method of cross section measurement by the CCD is proposed to make a cross reference with the CPA method. By applying these two methods, the wire deflection models can be established, and used for the corner cut control of wire-cut EDM to improve accuracy of the machined parts.

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7

Fatima, Anis, and Amir Iqbal Syed. "Identifying Direct Electrical Energy Demand in Wire-Cut EDM." January 2020 39, no. 1 (January 1, 2020): 171–78. http://dx.doi.org/10.22581/muet1982.2001.16.

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Non-traditional machining processes are popular for generating complex features on the work piece. With advances in material engineering, new ways of cutting technologies has been emerged. However, EDM (Electric Discharge Machining) has gained recognition for producing extraordinary surface finished, intricate part geometries with accuracy and its ability to cut through difficult to machined materials. However, like every product cycle, manufacturing processes also require energy to convert raw materials into finished product. In manufacturing operations, energy input gives carbon footprints which have an effect on our environment. It is observed that reducing energy consumption is becoming the main concern of manufacturers because of enforcing environmental laws and due to the economics of the processing. It is argued that world’s 70% of energy consumption is consumed by manufacturing sector. The aim of the work was to identify direct energy demands in wire cut EDM. The variability in energy demand was explored by operating wire cut EDM at no-load and loaded conditions.Stainless steel S304 was used as a work piece. Experiments were performed on three different wire-cut EDM.Molybdenum wire, brass wire and copper wire were used as an electrode wire and distilled water was used as a working fluid. During the experiment, electrical current was measured and the variation of power requirement was evaluated. Power required by different features of EDM was compared with the existing energy models and factors were identified that consume most of the electrical energy. Further, a comparison is made between traditional and non-traditional machining processes. This contribution will help to assess energy efficiency of EDM technology and identify priority areas for improvements. This work is also significant for machine tool designers for optimum utilization of energy,reduced environmental impact and reduced production cost of their machine tool.

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8

Liu, Chonglin, and Donald Esterling. "Solid modeling of 4-axis wire EDM cut geometry." Computer-Aided Design 29, no. 12 (December 1997): 803–10. http://dx.doi.org/10.1016/s0010-4485(97)00026-2.

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9

Satynarayana, Kosaraju, Kumkuma Rajkiran, Pujari Anil kumar, and D. Chakradhar. "A Role of cryogenic in Wire cut EDM process." E3S Web of Conferences 184 (2020): 01067. http://dx.doi.org/10.1051/e3sconf/202018401067.

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Novel techniques are being focused on the enrichment of the performance characteristics under different machining processes. Cryogenic is one of such novel practices that tunes the surface integrity with vast variations with the traditional machining processes. Dimensional accuracy, surface roughness, material removal rate with less reduction in scrap of material is one of the prior targets of production process. Wire cut Electro Discharge Machining (WEDM) is one method that satisfy with upgrading performance characteristics. In order to step-up these performance characteristics in attaining superior quality, cryogenics practices have collaborated with the WEDM process. Present paper deals with the reviews of the researchers that have been performed over cryogenic treated WEDM process. Effect of performance characteristics like pulse on, pulse off, current, voltage, wire tension, wire feed is discussed with relation to material removal rate, tool wear rate and surface roughness evolved. Key concept of paper is to include the research ideology with best feasible techniques that can prevail in production practice in order of contribute to the forthcoming researches in industrial and production departments.

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10

Puri, A. B., and B. Bhattacharyya. "Modelling and analysis of the wire-tool vibration in wire-cut EDM." Journal of Materials Processing Technology 141, no. 3 (November 2003): 295–301. http://dx.doi.org/10.1016/s0924-0136(03)00280-2.

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11

Sugimoto, Tatsunori, Toshiya Noro, Satarou Yamaguchi, Hideyoshi Majima, and Tomohisa Kato. "Spectroscopic Measurement of Electric Discharge Machining for Silicon Carbide." Materials Science Forum 615-617 (March 2009): 609–12. http://dx.doi.org/10.4028/www.scientific.net/msf.615-617.609.

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Diamond saw is generally used to make the silicon carbide (SiC) wafers from ingots, but it takes long time for cutting. We have used the electric discharge machining (EDM) to cut SiC. The cutting speed of EDM for SiC is almost 10 times faster than the diamond saw, and the surface roughness is 1/10 for the diamond saw. EDM cut SiC by the plasma produced between the wire and SiC material. The emissions from EDM plasma may involve much information for EDM cutting. We monitored the total light intensity by a photodiode, and observed the spectrum of the emission from EDM plasma by a visible spectroscopy. The discharge gas used helium and argon. In both discharges, the light emission was observed when the current was not zero. Also, many lines were observed Si I, Si II and C I from the SiC sample, and Cu I and Zn I from the wire. And, the electron temperature of EDM plasma was estimated to be under several eV because the observed lines were almost the emission from atoms. Also, the scars, which show the copper-alloy wire was hurt by discharge, were observed from the wire.

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12

OBARA, Haruki, Noriyuki ISHIZU, Tamotsu KAWAI, Tsuyoshi OHSUMI, and Takurou HAYASHI. "Simulation of Wire EDM. (3rd Report). Accuracy of Finish Cut." Journal of The Japan Society of Electrical Machining Engineers 34, no. 75 (2000): 30–37. http://dx.doi.org/10.2526/jseme.34.30.

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13

Patel, Harshadkumar, and Dhaval M. Patel. "Design a new wire cut EDM machine for turning operation." International Journal of Advanced Technology and Engineering Exploration 6, no. 53 (May 18, 2019): 84–91. http://dx.doi.org/10.19101/ijatee.2019.650031.

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14

Lok, Y. K., and T. C. Lee. "Processing of advanced ceramics using the wire-cut EDM process." Journal of Materials Processing Technology 63, no. 1-3 (January 1997): 839–43. http://dx.doi.org/10.1016/s0924-0136(96)02735-5.

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15

Ablyaz, T. R., and R. V. Lesnikov. "Influence of the wire EDM conditions on the cut width." Russian Engineering Research 36, no. 9 (September 2016): 786–87. http://dx.doi.org/10.3103/s1068798x16090033.

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16

Bergs, T., L. Welschof, T. Herrig, and A. Klink. "Energetic Characterization of Trim Cut Process Signals in Wire EDM." Procedia CIRP 95 (2020): 262–67. http://dx.doi.org/10.1016/j.procir.2020.02.281.

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17

Akram, Suhail, Shafi uddin, Syed Hussain Imran Jaffery, Mian Aamir Jalil, and Syed Waqar Hyder Kazmi. "Numerical Modeling and Experimental Validation in Orthogonal Machining of Aluminum Al 6061-T6 Alloy." January 2020 39, no. 1 (January 1, 2020): 179–94. http://dx.doi.org/10.22581/muet1982.2001.17.

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Non-traditional machining processes are popular for generating complex features on the work piece. With advances in material engineering, new ways of cutting technologies has been emerged. However, EDM (Electric Discharge Machining) has gained recognition for producing extraordinary surface finished, intricate part geometries with accuracy and its ability to cut through difficult to machined materials. However, like every product cycle, manufacturing processes also require energy to convert raw materials into finished product. In manufacturing operations, energy input gives carbon footprints which have an effect on our environment. It is observed that reducing energy consumption is becoming the main concern of manufacturers because of enforcing environmental laws and due to the economics of the processing. It is argued that world’s 70% of energy consumption is consumed by manufacturing sector. The aim of the work was to identify direct energy demands in wire cut EDM. The variability in energy demand was explored by operating wire cut EDM at no-load and loaded conditions.Stainless steel S304 was used as a work piece. Experiments were performed on three different wire-cut EDM.Molybdenum wire, brass wire and copper wire were used as an electrode wire and distilled water was used as a working fluid. During the experiment, electrical current was measured and the variation of power requirement was evaluated. Power required by different features of EDM was compared with the existing energy models and factors were identified that consume most of the electrical energy. Further, a comparison is made between traditional and non-traditional machining processes. This contribution will help to assess energy efficiency of EDM technology and identify priority areas for improvements. This work is also significant for machine tool designers for optimum utilization of energy,reduced environmental impact and reduced production cost of their machine tool.

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18

Kawata, Akiyoshi, Akira Okada, Yasuhiro Okamoto, and Haruya Kurihara. "Influence of Nozzle Jet Flushing on Wire Breakage in 1st-Cut Wire EDM from Start Hole." Key Engineering Materials 749 (August 2017): 130–35. http://dx.doi.org/10.4028/www.scientific.net/kem.749.130.

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In wire EDM process, it is important to smoothly exclude debris and bubbles generated in the working gap for keeping stable performance. Much debris stagnation in the gap would cause frequent occurrence of discharge concentration and secondary discharge, which results in unstable machining performance, such as frequent wire breakage, low removal rate, and low shape accuracy. Therefore, a jet flushing of working fluid using upper and lower jet nozzles has been conventionally applied for excluding the debris and bubbles from the machined kerf. Nevertheless, it is well known that the wire often breaks when the machined kerf length is a few mm from the start hole in 1st-cut wire EDM. The influence of machined kerf length on the flow field, the debris exclusion, and the wire behavier caused with hydrodyanamic force by the jet flushing should be made clear.In this study, variations of flow field in the kerf, the debris accumulation state and the wire deflection caused jet flushing with machined length were analytically investigated by CFD (computational fluid dynamics) and structural analysis when 1st-cut wire EDM was done from a small start hole. Moreover, the effects of machined kerf length on the wire deflection and wire breakage were discussed. Wire breakage frequency experiments showed that wire tended to frequently break at a certain machined kerf length, where the wire deflection rapidly increased and the debris particle residence time in the gap became long.

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19

Boopathi, S., and K. Sivakumar. "Optimal parameter prediction of oxygen-mist near-dry wire-cut EDM." International Journal of Manufacturing Technology and Management 30, no. 3/4 (2016): 164. http://dx.doi.org/10.1504/ijmtm.2016.077812.

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20

Chen, William, Shinichi Ninomiya, Shunsuke Nochi, Manabu Iwai, and Kiyoshi Suzuki. "Wire-EDM Properties of EC-PCD Made up of Boron Doped Diamond Particles." Advanced Materials Research 1017 (September 2014): 770–75. http://dx.doi.org/10.4028/www.scientific.net/amr.1017.770.

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It has been made clear that the EC-PCD composed of boron doped diamond particles improves the performance in the die sinking EDM and wire EDM in comparison with the existing standard PCD (S-PCD). However, the effect of the property improvement could not been evaluated quantitatively in the research reports in the past. Therefore, in this study, wire EDM cutting tests were conducted on the specimens of S-PCD and EC-PCD, in addition to the evaluation of cutting efficiency and cutting PCD surface, a detailed investigation of the cut surface properties of the PCD has been performed under the color 3D laser scanning microscope. In order to investigate effects of a grain size of the source diamond, EDM cutting experiments were conducted on the EC-PCD specimens of 4 different grain sizes. As a result, it was found that the cutting speed was higher in the case of EC-PCD than the case of S-PCD, e.g., by 20% and 40% respectively in the sample of 10μm and 25μm particle size. Also, in the case of the cut S-PCD surface, a groove due to the discharge is formed in the boundary of the tungsten carbide layer and the PCD layer. However, in the case of the cut EC-PCD surface, the groove did not appear in the boundary.

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21

Goswami, Amitesh, and Jatinder Kumar. "Surface Topography and Kerf Study of Nimonic 80A Using Wire-Cut EDM." Materials Science Forum 808 (December 2014): 35–41. http://dx.doi.org/10.4028/www.scientific.net/msf.808.35.

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Nimonic-80A is a nickel based super alloy which is specifically used in aerospace industry for its high strength to weight ratio and corrosion resistance. This paper presents the influence of process parameters of wire cut Electrical Discharge Machining (WEDM) during the machining of Nimonic 80A with brass wire as electrode and optimization of machining parameters on kerf width. Process parameters (pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed and wire tension) have been investigated using L27orthogonal array. With the assistance of Taguchi quality design, ANOVA and F-test, significant parameters affecting the kerf have been identified. The surface topography of machined samples has been studied in correlation with the rate of input energy into the spark.

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22

OBARA, Haruki, Toshihito KAMIWAKI, and Tsuyoshi OHSUMI. "Fundamental Study of Accuracy of Wire EDM. 1st Report: Relation between Cut Groove Width, Wire Vibration Amplitude and Gap length on Rough Wire EDM." Journal of The Japan Society of Electrical Machining Engineers 32, no. 70 (1998): 16–23. http://dx.doi.org/10.2526/jseme.32.70_16.

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23

Goswami, Amitesh, and Jatinder Kumar. "Trim cut machining and surface integrity analysis of Nimonic 80A alloy using wire cut EDM." Engineering Science and Technology, an International Journal 20, no. 1 (February 2017): 175–86. http://dx.doi.org/10.1016/j.jestch.2016.09.016.

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24

Mocian, Ioan, and Razvan Cazacu. "Aspects Regarding the Technologies on Wire EDM CNC Machines." Applied Mechanics and Materials 371 (August 2013): 255–59. http://dx.doi.org/10.4028/www.scientific.net/amm.371.255.

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The present paper presents an application for the computer aided generation of the programs for the wire cut EDM CNC machine ONA AE 300. The technological performances of this machine are highlighted, along with the implications of the work regimes on the generation of the machine programs. The application is developed for the AutoCAD environment, being written in VB.NET. The trajectories are defined as polylines between the Start and Stop points and the technological information is introduced by the user inside a dialog. The output of the application is a text file with the complete program for the ONA AE 300 machine.

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25

Sharma, Sahil, Umesh Kumar Vates, and Amit Bansal. "Parametric Optimization of EN-31 Steel in Wire Cut Electro Discharge Machining by Taguchi Technique." Advanced Science, Engineering and Medicine 12, no. 7 (July 1, 2020): 881–87. http://dx.doi.org/10.1166/asem.2020.2645.

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Amongst the various methods of machining, Electro Discharge Machining is the convenient alternatives for the industries due to non-contact of work piece and tool. In the study of various EDM processes the main target is to achieve the better finish of surface, high material removal rate and good dimensional accuracy by regulating the different input parameters. There are various applications of EDM such as aerospace parts, medical equipments, dies and moulds, nuclear and automobile industry. In this experimental study, a trial has made to look the impact of input factors like pulse-on, pulse-off, peak current, tension of wire on rate of material removal, gap current and time for machining. Taguchi (L9 OA) and Analysis of Variance technique were used to optimize the outcomes for wire cut EDM of EN-31 tool steel. The outcomes revealed that Ton and Toff are the leading cogent factor for material removal rate and gap current respectively.

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26

Karabulut, Ş., U. Gökmen, H. Karakoç, Ö. K. Kalkan, and R. Çitak. "Experimental Investigation of B$_{4}$C Particulate Reinforced Aluminium 6061 Based Composite Material in Wire-Cut EDM." METALLOFIZIKA I NOVEISHIE TEKHNOLOGII 37, no. 9 (August 18, 2016): 1239–51. http://dx.doi.org/10.15407/mfint.37.09.1239.

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27

Nallaiya, G., and K. S. Sekar. "Study of Machining on High Carbon High Chromium Die Steel Using Wire Cut EDM under Various Conditions." International Journal of Trend in Scientific Research and Development Volume-2, Issue-4 (June 30, 2018): 2135–40. http://dx.doi.org/10.31142/ijtsrd14581.

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28

IWATA, Yasushi, Haruki OBARA, Tsuyoshi OHSUMI, Yuhji MATSUDA, and Noriyuki ISHIZU. "Simulation of Wire EDM. (2nd Report). Accuracy of Rough Straight Cut Groove." Journal of The Japan Society of Electrical Machining Engineers 30, no. 64 (1996): 2–10. http://dx.doi.org/10.2526/jseme.30.64_2.

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29

Bhattacharya, Sujay, Abhishek Mishra, Tarvinder Singh, Srijit Bandyopadhyay, Santhosh Kumar, G. K. Dey, and V. Kain. "Simulation of residual stress using thermomechanical analysis on wire EDM cut surface." Materials Today: Proceedings 19 (2019): 462–67. http://dx.doi.org/10.1016/j.matpr.2019.07.636.

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30

Patil, Pankaj R., P. M. Solanki, and Dr S. P. Shekhawat. "Effects of Machining Parameters on Tool Steel D2 in Wire cut EDM." IOSR Journal of Mechanical and Civil Engineering 14, no. 03 (June 2017): 12–19. http://dx.doi.org/10.9790/1684-1403061219.

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31

Furutani, Katsushi, and Michiaki Tomoto. "Performance of Wire-Sawing of Glass Assisted by Electro-Chemical Discharge." Key Engineering Materials 523-524 (November 2012): 299–304. http://dx.doi.org/10.4028/www.scientific.net/kem.523-524.299.

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This paper deals with a combination machining method of slicing with electro-chemical discharge machining (ECDM). Glass and fine ceramics are hard to machine, and cracks are generated on their surface during cutting and grinding because of their brittleness and hardness. ECDM has been studied for machining such insulating materials. The authors have proposed a deposition method of WC layer by electrical discharge machining (EDM) with a compressed WC-Co powder as an electrode. The improvement of removal rate is expected by combining wire-sawing with ECDM. A silica glass rod was cut with a saw wire with the WC layer. The removal rate of the combination machining is larger than that of individual use of ECDM or wire sawing. The groove width by wire sawing was smaller than the others. Cracks were seldom observed on the bottom and side walls of the groove. Providing the fresh working fluid also assisted to decrease the cracks. The synergy of wire-sawing with ECDM was obtained.

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32

Durairaj, M., S. Elanthirayan, K. Aanand, and J. Poornachandran. "Optimization of Cutting Parameters in Wirecut EDM of D2 Die Steel Using Gravitational Search Algorithm." Applied Mechanics and Materials 592-594 (July 2014): 591–94. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.591.

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Wire cut Electrical Discharge Machining is one of the important manufacturing process which is used to obtain desired shape using electrical discharge (or) by continuous sparking. This paper deals with wire cut EDM of D2die steel using Zinc coated wire tool. Two conflicting objectives, surface roughness and kerf width, are simultaneously optimized. Experimentation was planned based on Taguchi’s L-9 orthogonal array. All the experiments has been conducted under different machining conditions of gap voltage, pulse ON time, and pulse OFF time. Wire feed, wire speed, resistance, wire tension, dielectric fluid pressure and cutting length are taken as fixed parameters. In this paper Gravitational Search Algorithm (GSA) is employed for optimising surface roughness and kerf width.

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33

MAITY, K. P., and M. CHOUBEY. "A REVIEW ON VIBRATION-ASSISTED EDM, MICRO-EDM AND WEDM." Surface Review and Letters 26, no. 05 (June 2019): 1830008. http://dx.doi.org/10.1142/s0218625x18300083.

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Electrical discharge machining (EDM) is an unconventional machining process used for machining of hard-to-cut materials. Both EDM and micro-EDM processes are extensively used for producing dies and molds, complex cavities, and 3D structures. In recent years, researchers have intensively focused on improving the performance of both micro-EDM and EDM processes. This paper reviews the research work carried out by the researchers on vibration-assisted EDM, micro-EDM, and wire EDM. The consolidated review of this research work enables better understanding of the vibration-assisted EDM process. This study also discusses the influence of vibration parameters such as vibration frequency and amplitude on the material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR). The important issues and research gaps in the respective area of research are also presented in this paper.

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34

Fan, Sheng Yao, Qiu Ju Zhang, and Hai Wei Chen. "Influence of Transverse Vibration of Axially Moving Electrode Wire on Machining Precision in Wire-Cut EDM." Applied Mechanics and Materials 80-81 (July 2011): 1010–15. http://dx.doi.org/10.4028/www.scientific.net/amm.80-81.1010.

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Many factors influence WEDM(Wire-cut Electrical Discharge Machining) machining precision, and the influence of various factors on the machining precision are expressed by wire electrode dynamic form ultimately. In this paper, the transverse vibration theoretical model of the axially moving electrode wire coupled with thermal stresses is established by the principle of Hamilton. The influence of various processing parameters on machining precision are analyzed and simulated. This study provides a relevant theoretical basis for optimizing processing parameters, reducing the wire vibration and improving machining precision of workpiece.

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35

CHAITANYA REDDY, M., and K. VENKATA RAO VENKATA RAO. "An overview of major research areas in Wire cut EDM on different materials." INCAS BULLETIN 12, no. 4 (December 4, 2020): 33–48. http://dx.doi.org/10.13111/2066-8201.2020.12.4.4.

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WEDM (Wire electrical discharge machining) is a precision machining method for cutting electrically conductive materials. It is an unconventional machining process that produces precision parts that match the dimensional tolerances of our designs within the range of ±0.0001mm. As the residual stress results in premature failure of parts, the WEDM is preferred for hard to machine materials such as Inconel, Nickel, and other Super alloys. In the present paper, earlier and recent work was reviewed, segregated and evaluated on the effect of wire material, diameter, dielectric fluid, wire wear, pulse on and off times and machining characteristics such as kerf size, machining efficiency, material surface characteristics, etc. This paper also focused on hybrid and ultrasonic-assisted WEDM used for machining of different materials. This paper discussed the major research studies in WEDM.

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36

Almeida, Sergio Tadeu, John Mo, Cees Bil, Songlin Ding, and Xiangzhi Wang. "Conceptual Design of a High-Speed Wire EDM Robotic End-Effector Based on a Systematic Review Followed by TRIZ." Machines 9, no. 7 (July 7, 2021): 132. http://dx.doi.org/10.3390/machines9070132.

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Exotic materials such as titanium offer superior characteristics that, paradoxically, make them hard-to-cut by conventional machining. As a solution, electric discharge machining (EDM) stands out as a non-conventional process able to cut complex profiles from hard-to-cut materials, delivering dimensional accuracy and a superior surface. However, EDM is embodied in CNC machines with a reduced axis and machining envelope, which constrains design freedom in terms of size and shape. To overcome these CNC constraints, traditional machining using six-axis industrial robots have become a prominent research field, and some applications have achieved cost efficiency, an improved envelope, and high flexibility. However, due to the lack of stiffness and strength of the robot arm, accuracy, material rate removal, and surface finishing are not comparable to CNC machining. Therefore, the present study investigates the design of a novel WEDM combined with six-axis robotic machining to overcome the limitations of traditional robotic machining and enhance EDM applications. This study extends the work of a conference paper to confirm potential outcomes, quantifying and ranking undesired interactions to map technical problems and applying the TRIZ approach to trigger solutions. Finally, an effective robotic end-effector design is proposed to free EDM from CNC and deliver robotic machining as a flexible and accurate machining system for exotic materials.

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37

Nandakumar, C., B. Mohan, and S. Srisathirapathy. "Optimization of Process Parameters of Titanium Alloy Grade 5 Using CNC Wire-Cut EDM." Advanced Materials Research 984-985 (July 2014): 56–61. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.56.

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Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact strength are increasing. As these materials pose severe difficulty to be machined by conventional methods, Wire-cut Electric Discharge Machining (Wire EDM) machines are employed to machine them. The ultimate requirement of any machining process being fine surface finish, is accurately satisfied by wire-cut EDM process. Hence this project aims at obtaining the best surface finish by optimizing various process parameters affecting the machining conditions. With the assistance of Taguchi quality engineering, various number of experiments will be conducted by varying the process parameters at various levels. The output response variable being surface roughness, will be measured for all the number of experiments conducted. As the lowest value of surface roughness indicates the best surface finish, the optimum parameter level combination would be analyzed which gives desired surface finish. These optimized values of various parameters would then be used in performing machining operation in order to obtain desirable outputs.

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ABLYAZ, TIMUR RIZOVICH, and KARIM RAVILEVICH MURATOV. "THE TECHNOLOGICAL QUALITY CONTROL OF STACK CUTTING BY WIRE ELECTRICAL DISCHARGE MACHINING." Surface Review and Letters 24, no. 05 (October 19, 2016): 1750060. http://dx.doi.org/10.1142/s0218625x17500603.

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Electrical discharge machining (EDM) of a stack allows achieving high precision and quality of cut surfaces and, therefore, this method is indispensable for state-of-the-art mechanical engineering. The procedure of EDM is carried out with wire-cutting machines. The characterization of constructive parameters of a stack of material and applying of an efficient cutting regime are the most important preconditions providing high precision of EDM. The goal of this work is the improvement of quality and efficiency of wire electrical discharge machining (WEDM) technology by theoretical and experimental studies of the WEDM process. The subsequent development of theoretical and empirical models allowing for the calculation of the quality parameters of treated surfaces is realized. It is shown that the main characteristics of cut surfaces are the roughness, size precision, error profile and structure of a surface layer. For the first time, the regression dependencies between the main parameters of the WEDM process (pulse [Formula: see text]-time [Formula: see text], off-time [Formula: see text], the height of the stack and the physicomechanical properties of the cut materials are obtained. The experimental study of WEDM confirms the results of mathematical modeling. It is proved experimentally that at an interlayer gap higher than 0.1[Formula: see text]mm, the cutting process stability is decreasing whereas the probability of the electrode fracture is increasing. However, it is found that at [Formula: see text]s and [Formula: see text]s, a stable cutting regime leading to bundling of the stock materials made from steel 65Γ can be realized.

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VS Ram Prasad, A., Koona Ramji, and B. Raghu Kumar. "Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method." International Journal of Engineering & Technology 7, no. 2.8 (March 19, 2018): 10. http://dx.doi.org/10.14419/ijet.v7i2.8.10316.

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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.

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Wu, Yung-Yi, Tzu-Wei Huang, and Dong-Yea Sheu. "Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool." Micromachines 11, no. 7 (July 11, 2020): 675. http://dx.doi.org/10.3390/mi11070675.

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Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15.

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Durairaj, M., A. K. S. Ansari, and M. H. Gauthamkumar. "Parametric optimization of wire cut electrical discharge machining." International Journal of Engineering & Technology 3, no. 2 (April 26, 2014): 212. http://dx.doi.org/10.14419/ijet.v3i2.1807.

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Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

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Zhao, Jian Chuang, Jian Dong Hu, Fan You Meng, and Yao Min Wang. "Machinability and Material Removal Mechanism of Face Centred Cubic (FCC) Conductive Ceramic TiBCN in EDM Processing." Key Engineering Materials 680 (February 2016): 147–51. http://dx.doi.org/10.4028/www.scientific.net/kem.680.147.

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Fcc-TiBCN powder synthesized by boronizing of Ti was pressured into monolithic block by hot pressing (HP) method. Then the block material was machined by wire-cut EDM. The machinability and the material removal mechanisms were discussed of Fcc-TiBCN block in wire-cut EDM. Results show that the machinability of Fcc-TiBCN is satisfying. The discharge current has little relationship on surface roughness in the range of factory-adjusted optimum settings. The discharge duration and pulse interval time play an important role on the quality of machined surface and EDM machining efficiency. In order to obtain excellent quality of the machined surface, the number of power tube turned on can not exceed 6, and the pulse interval time must be as long as possible. The mini roughness of machined surface is 0.4μm～0.6μm as the number of power tube turned on is 5, the pulse interval time and discharge duration is set in the range of 20～22μs and 65～75μm, respectively. There are three material removal mechanisms of TiBCN conductive ceramic in the EDM machining process: spalling, melting and evaporation. Spalling is the main mechanism resulted by thermal stress superposing.

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Luo, Hong Ping, Zhi Xiong Zhou, Yong Jun Zhang, and Zhong Ning Guo. "Wire Electrical Discharge Machining (Wire EDM) Cutting of Flexures for a Rotary Flexural Bearing Fabrication." Advanced Materials Research 314-316 (August 2011): 1727–33. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.1727.

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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.

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Liu, J. F., and Y. B. Guo. "Process Capability of Wire-EDM of NiTi Shape Memory Alloy at Main Cut and Trim Cut Modes." Procedia Manufacturing 1 (2015): 904–14. http://dx.doi.org/10.1016/j.promfg.2015.09.083.

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KAWAKUBO, Hideki, and Tatsuya YOMOGIDA. "611 Partial Polishing of Wire Cut EDM Plane by Magnetic Field Assisted Machining." Proceedings of Conference of Hokuriku-Shinetsu Branch 2007.44 (2007): 239–40. http://dx.doi.org/10.1299/jsmehs.2007.44.239.

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Raju, B. Naga, M. Raja Roy, S. Rajesh, and K. Ramji. "Optimization of Machining Parameters for Cutting AMMC’s on Wire Cut EDM using RSM." International Journal of Engineering Trends and Technology 23, no. 2 (May 25, 2015): 82–89. http://dx.doi.org/10.14445/22315381/ijett-v23p216.

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Lenin, Nagarajan, Gurusamy Selvakumar, and Velayutham Balasubramanian. "Investigation on corner accuracy in wire cut EDM of AISI D3 tool steel." International Journal of Rapid Manufacturing 9, no. 1 (2020): 58. http://dx.doi.org/10.1504/ijrapidm.2020.10026154.

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Selvakumar, Gurusamy, Velayutham Balasubramanian, and Nagarajan Lenin. "Investigation on corner accuracy in wire cut EDM of AISI D3 tool steel." International Journal of Rapid Manufacturing 9, no. 1 (2020): 58. http://dx.doi.org/10.1504/ijrapidm.2020.104426.

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Azam, Muhammad, Mirza Jahanzaib, Junaid Ali Abbasi, Musharaf Abbas, Ahmad Wasim, and Salman Hussain. "Parametric analysis of recast layer formation in wire-cut EDM of HSLA steel." International Journal of Advanced Manufacturing Technology 87, no. 1-4 (February 27, 2016): 713–22. http://dx.doi.org/10.1007/s00170-016-8518-3.

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Abbasi, Junaid Ali, Mirza Jahanzaib, Muhammad Azam, Salman Hussain, Ahmad Wasim, and Musharaf Abbas. "Effects of wire-Cut EDM process parameters on surface roughness of HSLA steel." International Journal of Advanced Manufacturing Technology 91, no. 5-8 (December 24, 2016): 1867–78. http://dx.doi.org/10.1007/s00170-016-9881-9.

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