Complex phenomena study in dielectric fluid from gap during the W-EDM processing in ultrasonic field

Nani, Viorel-Mihai

doi:10.1007/s00170-017-0114-7

Cited by 8 publications

(3 citation statements)

References 21 publications

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“…It uses the special technique of cutting the metal via the sparks created between the workpiece and electrode (i.e., wire form). These sparks erode the material, and the di-electric fluid acts as an eroded metal carrier [5]. The IP, voltage (v), Toff, Ton, and flow of dielectric fluid are the parameters that play major roles in the WEDM process.…”

Section: Introductionmentioning

confidence: 99%

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Kosaraju¹,

Bobba²,

Salkuti

2023

Materials

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Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.

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Section: Introductionmentioning

confidence: 99%

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Kosaraju¹,

Bobba²,

Salkuti

2023

Materials

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“…As a solution, electric discharge machining (EDM) has successfully replaced conventional processes to better machine hard-to-cut materials. By definition, EDM consists of a non-conventional process capable of cutting any conductive material with at least 0.01 S/cm [3] by gradually melting particles of the workpiece surface by thermal energy generated by a series of high-frequency discharges [4]. As the name suggests, in wire EDM, a thin and flexible wire plays the role of the electrode, allowing it to cut the workpiece's surroundings without evaporating unused portions of the rare and expensive exotic material.…”

Section: Introductionmentioning

confidence: 99%

Control design of a reciprocating high-speed wire feed system for 7-axis robotic electric discharge machining

Almeida

Ding

et al. 2022

Int J Adv Manuf Technol

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For decades, researchers have struggled to solve 6-axis robotic vibration while machining hard-to-cut materials. On the other hand, wire electric discharge machining (WEDM) stands out as a non-conventional machining process able to cut large and complex profiles of any conductive hard-to-cut material with minor non-contact forces. Thus, WEDM is a promising process to be combined into a robot to overcome vibration and low accuracy. However, the robot characteristics of a high degree of freedom combined with payload limitation oblige to separate the heavy wire winding system from the robot end-effector, demanding an equally high degree of freedom and unconventional solutions to feed and control the wire electrode. This study designs and reports experimental findings of the first robotic WEDM apparatus based on a high-speed winding system with 600 m of wire length, capable of controlling the wire speed from 1 to 10 m/s and wire tension from 0.1 to 10 N. The system adopts flexible outer cases to travel and reciprocate the wire into a 7-axis robotic system composed of a 6-axis robot and an external rotating axis. The proposed design is a highly dynamic process whose wire tension and speed are achieved by a hybrid controller to cope with the non-linear relation of speed and tension provided by the magnetic clutch. It combines a regression open-loop control for optimality and wire breakage avoidance with a closed-loop control to guarantee admissibility while coping with wire friction disturbances. The findings review a novel wire winding system capable of controlling usual wire disturbance and stepped surface of reciprocating high-speed WEDM as well as additional friction and elastic behaviour of the flexible case, delivering wire tension of ± 12% along with stable EDM process and uniform surface roughness between wire reciprocation areas with a Ra of 2.94 μm. Potential adoption of the method can finally make 6-axis robots a feasible and advantageous technique compared to computer numeric control (CNC) while shaping monolithic and complex workpieces of conductive and hard-to-cut materials.

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“…Next, the electrode is connected to the machine head to perform linear up and down movements towards the workpiece until a small distance gap where the sparkles can occur. The process will gradually melt portions of the workpiece surface by repeating this kinematic several times to deploy high-frequency electric discharges [3]. Unlike traditional machining, EDM offers nearly no cutting forces, while mechanical stresses, chatter, and vibrations are eliminated [4].…”

Section: Introductionmentioning

confidence: 99%

Accurate vibration-free robotic milling electric discharge machining

Almeida

Bil

et al. 2022

Int J Adv Manuf Technol

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Traditional computer numeric control (CNC) machines have high accuracy but are limited by workpiece size and axes. Therefore, many researchers attempted to equip six-axis industrial robots (IRs) with milling end-effectors to explore the robot’s large and flexible working envelope. However, IRs lack stiffness and have limited force, resulting in low accuracy, poor surface roughness (SR), and low material removal rate (MRR). On the contrary, electric discharge machining (EDM) is a non-conventional process capable of shaping complex profiles in any conductive material. Since the EDM process has no physical contact between the electrode and the workpiece, it can machine diverse hard-to-cut materials accurately and free of vibration. However, to this day, EDM is found in limited conditions of CNC machines only. Thus, this research investigates a synergistic combination of IR and milling EDM. Adopting advanced CAM tools and offline programming, it examines pre-designed electrodes working analogue to conventional milling to perform the desired machining by intricate cutting paths. The results deliver a robotic machining technique able to cut hard materials using small industrial robots yet free of vibration and not pose dependent.

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Complex phenomena study in dielectric fluid from gap during the W-EDM processing in ultrasonic field

Cited by 8 publications

References 21 publications

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Control design of a reciprocating high-speed wire feed system for 7-axis robotic electric discharge machining

Accurate vibration-free robotic milling electric discharge machining

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