A new approach for Micro-WEDM control based on Real-Time estimation of material removal rate

Hoang, Kien Trung; Yang, Seung-Han

doi:10.1007/s12541-015-0032-2

Cited by 27 publications

(17 citation statements)

References 19 publications

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“…Normal % Probability (2) where, v = gap voltage (V) and t = wire tension (%). Figure 2a and 2b shows the diagnostic test through the normal probability of residual plot and residual versus predicted plot respectively.…”

Section: Studentized Residualsmentioning

confidence: 99%

“…The demand in fabricating complex micro parts with high accuracy using electrical discharge machining (EDM) is increasing especially in biomedical, electronics, and aerospace industry [1][2][3][4]. EDM is preferable due to a non-contact machining operation where electrical energy is used to produce a series of discrete sparks between the tool electrode and the workpiece [5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

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Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Ali¹,

Banu²,

Salehan³

et al. 2018

J. MECH. ENG. SCI.

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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.

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Section: Studentized Residualsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Ali¹,

Banu²,

Salehan³

et al. 2018

J. MECH. ENG. SCI.

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“…Electrical discharge machining (EDM) process has the ability to fabricate high-precision products for communication, aerospace, and automotive industries [1][2][3][4][5][6]. It is a thermal machining process where the machined area of the workpiece is removed by the thermal energy created by the electrical spark [4,7,8]. The electrical sparking process is a repetitive and discrete process which is carried out in dielectric fluid [4,[7][8][9].…”

Section: Introductionmentioning

confidence: 99%

“…It is a thermal machining process where the machined area of the workpiece is removed by the thermal energy created by the electrical spark [4,7,8]. The electrical sparking process is a repetitive and discrete process which is carried out in dielectric fluid [4,[7][8][9].…”

Section: Introductionmentioning

confidence: 99%

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Stability of micro dry wire EDM: OFAT and DOE method

Banu

Ali

Rahman

et al. 2020

Int J Adv Manuf Technol

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Micro dry wire electrical discharge machining (μDWEDM) is an environmental-friendly machining process where gas is used as the dielectric fluid instead of liquid. In this process, certain modifications of wire electrical discharge machining (WEDM) are required during the machining operation for stable machining. In μDWEDM, the process is considered stable if the machining is continuous without any interruption due to wire breakage or wire lag. However, in the present state of the arts, stable and smooth machining process using μDWEDM remains a critical issue. Hence, the objectives of this research are to establish a stable μDWEDM process using two different experimental approaches: one-factor-at-a-time (OFAT) and design of experiment (DOE) method. The investigation was performed on a stainless steel (SS304) with a tungsten wire as the electrode using integrated multiprocess machine tool, DT 110 (Mikrotools Inc., Singapore). Types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, wire speed, gap voltage, and capacitance were the controlled parameters. The machining length of the microchannels was measured using scanning electron microscope (SEM) (JEOL JSM-5600, Japan). Analysis based on these two experimental approaches shows that stable μDWEDM process is achievable when the types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, and wire speed remain as the fixed parameters while the capacitance and gap voltage remain as the controlled parameters.

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