Machining and Characterization of Double-Helical Grooves on Cylindrical Copper Parts by Wire Electric Discharge Turning

Abstract:

In the work, the design and development of a novel Wire-EDM setup with double-wire guide discs is presented. It facilitates sparks to be generated between the workpiece and wire at two locations separated by the helical pitch distance. This sparking causes two helical grooves to be generated simultaneously on the surface of the workpiece when it is given suitable rotational speed and table feed. In this work, machining is carried out on rods of 1.5 mm diameter. Helical groves with helix angles ranging from 35 to 500 were generated and characterized. This method of machining the double helical grooves with a single pass reduces the machining time and eliminates the complexities involved in machining one groove at a time. It was observed that the proposed method is suitable for machining double helical grooves with helix angles in the range of 40 - 50°. The parts produced by the mentioned method can be used as EDM tools for generation of high aspect ratio holes in turbine blades and injection nozzles.

• Periodical: Materials Science Forum (Volume 1009)
• Pages: 117-122
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.1009.117
• Online since: August 2020
• Authors: Jacob Serah Krupa, G.L. Samuel*
• Keywords: Double Helix Machining, Helical Pitch, Wire Electric Discharge Turning, Wire Guide Discs

References

[1] X. Zhang, Y. Ueyama, T. Shinshi, A. Shimokohbe, T. Sato and H. Miyake: High-speed and high-accuracy EDM of micro holes by using a 5-DOF controlled maglev local actuator Mater. Sci. Forum Vol. 626 (2009) p.255–260.

DOI: 10.4028/www.scientific.net/msf.626-627.255

[2] S. Barman, N. Hanumaiah and A.B. Puri: Investigation on shape, size, surface quality and elemental characterization of high-aspect-ratio blind micro holes in die sinking micro EDM. Int J Adv Manuf Technol Vol. 76 (2013), p.115–126.

DOI: 10.1007/s00170-013-5243-z

[3] P.D. Urbina Coronado, J. Martínez García, E. Vargas Tinoco and P. Orta-Castañon; Online monitoring of a micro-EDM machine: Machining diagnosis on the cloud based on discharge currents and voltages. Manuf Lett Vol. 15 (2018), p.115–118.

DOI: 10.1016/j.mfglet.2017.12.004

[4] G. Malayath, A.M. Sidpara and S. Deb: Fabrication of micro-end mill tool by EDM and its performance evaluation. Mach Sci Technol Vol. 1 (2019), p.1–26.

DOI: 10.1080/10910344.2019.1636269

[5] A. Perveen and M.P. Jahan: Application of Box Behnken Design to Model Crater Size Generated during Micro-EDM of NI-X Alloy. Int J Mech Eng Robot Res Vol. 7 (2018), p.229–234.

DOI: 10.18178/ijmerr.7.3.229-234

[6] S. Plaza, J.A. Sanchez, E. Perez, R. Gil, B. Izquierdo, N. Ortega and I. Pombo: Experimental study on micro EDM-drilling of Ti6Al4V using helical electrode. Precis Eng Vol. 38 (2014), p.821–827.

DOI: 10.1016/j.precisioneng.2014.04.010

[7] J.C. Hung, J.K. Lin, B.H. Yan, H.S. Liua and P.H. Ho: Using a helical micro-tool in micro-EDM combined with ultrasonic vibration for micro-hole machining. J Micromechanics Microengineering Vol. 16 (2006) p.2705–2713.

DOI: 10.1088/0960-1317/16/12/025

[8] M.Y. Ali, A. Banu, M. Shaffiq, M.A. Rahman, M. Konneh and M. Salehan: Investigation of taper angle in dry micro wire EDM. Int J Mech Eng Robot Res Vol. 8 (2019), p.725–728.

DOI: 10.18178/ijmerr.8.5.725-728

[9] Y. Sun and Y.Gong: Experimental study on fabricating spirals microelectrode and micro-cutting tools by low speed wire electrical discharge turning. J Mater Process Technol Vol. 258 (2018) p.271–285.

DOI: 10.1016/j.jmatprotec.2018.04.007

[10] V. Janardhan and G.L. Samuel: Pulse train data analysis to investigate the effect of machining parameters on the performance of wire electro discharge turning (WEDT) process. Int J Mach Tools Manuf Vol. 75 (2010) p.775–788.

DOI: 10.1016/j.ijmachtools.2010.05.008

[11] K.Z. Zhang, B. Zhu, Y.K. Wang, and Z.L. Wang: Exceeded slender micro-shaft machined by micro-EDM process, Mater. Sci. Forum Vol. 770 (2014) p.352–356.

DOI: 10.4028/www.scientific.net/msf.770.352

[12] T. Masuzawa, M. Yamaguchi and M. Fujino: Surface finishing of micropins produced by WEDG. CIRP Ann - Manuf Technol Vol. 54 (2005) p.171–174.

DOI: 10.1016/s0007-8506(07)60076-6

[13] A.B. Puri and B. Bhattacharyya: Modelling and analysis of the wire-tool vibration in wire-cut EDM. J Mater Process Technol Vol. 141 (2003) p.295–301.

DOI: 10.1016/s0924-0136(03)00280-2