Papers by Keyword: Micro WEDM

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Authors: Guan Xin Chi, Guo Hui Cao, Shi Chun Di, Zhen Long Wang
Abstract: Generator is one of the key factors in Micro WEDM, which can affect machining quality, precision and efficiency largely. The factors influencing discharge energy are discussed and analyzed, the pulse addition method increasing energy density under maintaining the single pulse energy is advanced. To reduce the influence of voltage to single pulse energy, the gap voltage is also controlled. The generator is designed and the validating experiment shows this generator can increase machining efficiency and quality to a certain extent.
Authors: R.N. Huang, T. Wang, B. Liu
Abstract: A Micro WEDM (Micro Wire Electrical Discharge Machining) CNC system is presented in this paper. Its hardware platform adopted PC with movement control card. For Micro WEDM system is a typical multitasking and real-time system, the CNC software adopted multithread and module structure to perform the parallel tasks and real-time tasks. It also adopted fuzzy control algorithm to control the feeding speed and acceleration. Practical proved that the CNC system is not only low cost and easy to development, but also satisfied the need of Micro WEDM.
Authors: Shi Chun Di, Xu Yang Chu, Dong Bo Wei, Hong Zhang
Abstract: In Micro Wire Electrical Discharge Machining (Micro-WEDM), the kerf width varies with different machining parameters, which will greatly influence the machining precision. In order to study the kerf variations in Micro-WEDM, the influence of kerf variation is analyzed and the experiment considering the kerf width and machining speed are performed on self-developed micro-WEDM under different machining parameters. With the reference of the experiment results, 32μm wide slot is machined with Φ30μm wire-tool on stainless steel workpiece.
Authors: X.S. Geng, Yu Kui Wang, Zhen Long Wang, De Bin Shan
Abstract: This paper discusses a processing preparation for micro-electrode array fabrication by micro wire electrical discharge machining. Based on a self-developed micro-WEDM machine tool and adopted thin tungsten wire electrode of 30μm in diameter, a series of experiments on micro-electrode array machining are introduced. The relationship between the discharge gap and working area of wire discharge under given voltage is investigated. The examination for micro-girder structure forming process has gone along and the axle journal's minimized width of least micro girder which could not bring on machining flexural thermal deformation has been obtained. The clamping method of work-piece intended for electrode array fabrication is analyzed and a special fixture is designed. The factors affecting forming accuracy are summarized. An amounted 5×5 squared-disk-type micro-electrode array structure with a high aspect ration, namely 20μm in axle journal width and 500μm in length of a single electrode, has been machined successfully.
Authors: Shi Chun Di, R.N. Huang, Guan Xin Chi, W.S. Zhao
Abstract: A new Micro-WEDM machine is developed in this paper. Therefore, experiment can be done on this machine. Especially, the surface characteristics of work-pieces are analyzed in detail. The Micro-WEDM can machine micro slot easily. In addition, all kinds of micro shaped holes, micro gears, complex micro parts and dies are machined to check its processability. A micro gear can be easily fabricated by micro-forming method with the micro gear dies fabricated by micro-WEDM, and get well performance, which indicates that micro parts machined by Micro-WEDM meet the requirements of micro instrument and device.
Authors: Mohammad Yeakub Ali, W.Y.H. Liew, S.A. Gure, B. Asfana
Abstract: This paper presents the estimation of kerf width in micro wire electrical discharge machining (micro WEDM) in terms of machining parameters of capacitance and gap voltage. An empirical model is developed by the analysis of variance (ANOVA) of experimental data. Using a wire electrode of 70 µm diameter, a minimum kerf width is found to be 92 µm for the micro WEDM parameters of 0.01 µF capacitance and 90.25 V gap voltage. Around 30% increament of the kerf is found to be high. The analysis also revealed that the capacitance is more influential parameter than gap voltage on kerf width produced by micro WEDM. As the gap voltage determines the breakdown distance and affects the wire vibration, the wire vibration factor is to be considered in the analysis and in formulation of model in future study.
Authors: Yu Kui Wang, Zhen Long Wang, Mao Sheng Li, Wei Liang Zeng, M.H. Weng
Abstract: In the paper, in order to overcome machining limits in throughput and precision because of positioning error and tool wear of a single tool electrode, a method for the microelectrode array fabrication by micro-WEDM is described and assessed. Characteristics of the microelectrode array fabrication by micro-WEDM, such as machining open voltage, pulse peak current, discharge duration and servo feed rate so on, are investigated through a series of experiments. A 10 10 squared electrode array is machined by micro-WEDM and the width of each squared electrode is about 40µm. The microelectrode array with good quality is obtained by applying decreased open voltage and peak current, increased discharge duration and optimized machining speed. Then micro hole-array is processed by applying obtained electrode array in micro-EDM method. The diameter of each squared hole in the array is about 50 µm due to appropriate control strategy that per micro pulse energy is decreased and periodic jump-down is applied during the machining process. Experiments have demonstrated that the combination process of microelectrode array fabricated by micro-WEDM and micro-hole array done by micro-EDM is a novel method of process which makes it more feasible and efficient to fabricate microelectrode array and high-density hole-array.
Authors: Guan Xin Chi, Shi Chun Di, Guo Hui Cao, Zhen Long Wang
Abstract: This paper analyzes the cause of overshoot and retarded response in controlling piezoelectric ceramic motor with PMAC card in micro WEDM. The model of start-stop control is presented, and the servo control card with start-stop control is also developed. The model reserved the advantages of traditional PID control, and overcome the problems of overshoot and retarded response. It has been verified by machining that system overshoot is less than 3 pulses and response time is less than 1 second.
Authors: P. Sivaprakasam, P. Hariharen, S. Kathikheyen, S. Balusamy
Abstract: Micro Electrical discharge machining (µEDM) is an electro thermal process, the cutting force is negligibly small and material removal occurs irrespective of hardness of work piece material .Micro electrical discharge machining process is capable of machining of complex shape, which is difficult to machine in conventional machining process. Last decade, the EDM process involved demand for machining requirements with short period. Since the major risk of wire breakage, deflections of electrodes were affecting the performance accuracy of EDM operation. This paper describe about a comprehensive review of micro electro discharge machining process and its process optimization techniques used for last 10 years. Micro electro discharge machining has more important given to difficult to machine materials. In order to improve the surface integrity and performance of process, need to select proper process parameters. It reports on the Micro EDM research involving the optimization of the process parameters surveying the influence of the various factors affecting the machining performance and productivity.
Authors: Palani Sivaprakasam, P. Hariharan
Abstract: This paper presents modeling and analysis of machining characteristics of Micro Wire Electro Discharge Machining (Micro-WEDM) process on Aluminium alloy (AL 2024 T351) using the Response Surface Methodology (RSM) and Artificial Neural Network (ANN). The input variables of Micro-WEDM process were voltage, capacitance and feed rate. The surface roughness is considered as a response variable. Experiments were carried out on Aluminium alloy using Central Composite Design (CCD). The RSM and ANN models have been developed based on experimental designs for surface roughness. Analysis of variance (ANOVA) has been employed to test the significance of RSM model. It has been found out that all the three process parameters are significant and their interaction effects are also significant on the surface roughness. Finally predicted values were compared with both modeling methodologies RSM and ANN.
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