A New Pulse Discriminating System for Micro-EDM

Yeo, Song Huat; Aligiri, E.; Tan, Peng; Zarepour, H.

doi:10.1080/10426910903130164

Cited by 53 publications

(21 citation statements)

References 16 publications

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“…Therefore, it is considered to be one of the significant methods for machining micro and submicro components of hard, electrically conducting materials. However, the sparks that occur between the tool and the workpiece have a strong effect on the stability of machining, and it is essential to observe it throughout the process [1]. In order to apply micro-EDM for industrial cases, detail research work has been carried out to develop adequate=reliable data related to the machining parameters of material removal rate (MRR), heat-affected zone (HAZ), and dimensional accuracy.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Electrode Specific Performance in Micro-EDM of Die-Steel

Kadirvel

Hariharan

Gowri

2013

Materials and Manufacturing Processes

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Recent advancement in manufacturing industries has given rise to miniaturized and light weight products with increasing high engineering applications. The miniaturized products demand innovative manufacturing methods. Microelectric discharge machining (micro-EDM) is one of the most powerful technologies capable of fabricating microstructures/parts. Experiments have been conducted on the machining of EN24 die steel with different electrodes such as tungsten, copper, copper tungsten, and silver tungsten in micro-EDM setup. The process performance was estimated based on material removal rate (MRR), circularity, overcut, and heat-affected zones (HAZ) of micromachined holes. Further, the outcome of various machining parameters such as gap voltage, capacitance, threshold, and feed rate of the electrode has also been investigated. The results revealed that the Cu as electrode achieved maximum MRR followed by AgW, CuW, and W, respectively.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Electrode Specific Performance in Micro-EDM of Die-Steel

Kadirvel

Hariharan

Gowri

2013

Materials and Manufacturing Processes

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“…This may be primarily due to formation of localized debris-rich regions [13] and secondarily due to increase in domination of overlapping of craters with the progress in machining [11]. Under such condition, assuming a constant VRD may cause in either over or under estimation of RT V and that will eventually lead to an error in tool wear monitoring.…”

Section: Introductionmentioning

confidence: 93%

A New Approach of Tool Wear Monitoring and Compensation in RµEDM Process

Nirala

Saha

2015

Materials and Manufacturing Processes

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This paper presents a new approach of tool wear compensation, based on 'volume removal per discharge' ( VRD ) in 'reverse-micro-electrical-discharge machining'. In this process, a plate with pre-drilled micro-hole is used as a tool, the erosion of which limits the fabrication of desired height of micro-rod(s). Therefore, in order to achieve the dimensional accuracy of this micro-rod(s), such tool plate wear needs to be compensated.Since this approach is based on the real-time estimation of volume removal from workpiece, which is obtained by multiplying the number of 'contributing' pulses with the VRD, therefore, an accurate estimation of VRD is very much essential for availing correct tool wear compensation. In this work, VRD is estimated by considering two new aspects; the number of actual 'contributing' pulses and the variation of VRD with machining depth. These pulses are identified by a 'pulse discriminating' system developed in house. The real-time material removal volume from workpiece is then used to estimate the 'real-time height' of micro-rods after considering the over cut and taperness of each micro-rod. The proposed method is also compared with the normal machining method and 'uniform wear method' and found to be more accurate with a negligible error of maximum 1.7%.

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“…τ is the time constant, which is determined by R and C as (13) In an RC circuit, the time for a capacitor to be fully charged (charging time) or to fully discharge (discharging time) is approximately five times the time constant τ. In EDM, charging and discharging are performed with two different resistors.…”

Section: Reference Discharge Frequency Of the Rc-circuitmentioning

confidence: 99%

“…More discharge parameters are also involved, the monitoring of the process is more accurate and the efficiency of the gap control has been significantly improved. [13][14][15][16][17] However, in most of the EDM machine used todays, the electrode cannot be fed with a constant feedrate during the machining process, as it can be done in traditional CNC machining. This wastes a significant amount of effective working time.…”

Section: Introductionmentioning

confidence: 99%

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

Hoang

Yang

2015

Int. J. Precis. Eng. Manuf.

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This paper describes a new approach for controlling a micro wire electrical discharge machining (µ-WEDM) process. In this approach, the relative feedrate of electrodes was controlled based on the real-time estimation of material removal rate and the identification of the workpiece height. An assisted vibration was applied to the workpiece, eliminating the limitation of a small discharge gap. This allows the electrode to be moved continuously, which cannot be performed in conventional WEDM. To verify the efficiency of the system, two workpieces with different shapes were used. For one workpiece, the height was varied linearly, whereas for the other, the height was varied non-linearly. The discharge current, discharge voltage, and number of discharge pulses were measured using current and voltage probes. The signal was uploaded to a computer through data acquisition devices, and a LabVIEW program was developed to estimate the feedrate and control the stages. The experimental results showed that the developed system worked effectively, with high machining stability and efficiency.

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A New Pulse Discriminating System for Micro-EDM

Cited by 53 publications

References 16 publications

Experimental Investigation on the Electrode Specific Performance in Micro-EDM of Die-Steel

Experimental Investigation on the Electrode Specific Performance in Micro-EDM of Die-Steel

A New Approach of Tool Wear Monitoring and Compensation in RµEDM Process

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

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