Effect of low frequency vibration on micro EDM drilling

Lee, Pyeong An; Kim, Young-Han; Kim, Bo Hyun

doi:10.1007/s12541-015-0335-3

Cited by 37 publications

(9 citation statements)

References 19 publications

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“…The exact optimal value is determined using Eq. (9). The accuracy of the calculation and experimental results are consistent and the largest calculation error is 8.24% (table 8).…”

Section: Effect Of Process Parameters On Zjsupporting

confidence: 60%

“…The low-frequency vibration (F = 10-70 Hz) is assigned to the workpiece in l-EDM drilling, which significantly improves the flushing efficiency of the dielectric fluid flow in addition to enhancement of the stability of the machining process. This contributes to a 70% reduction in the machining time relative to conventional EDM [9]. Compared with conventional WEDM, WEDM with lowfrequency vibration (F = 0-80 Hz) assigned to an Inconel 718 workpiece demonstrated that MRR is improved by 66.20% and the adhesion of the chip to the machined surface is significantly reduced [10].…”

Section: Introductionmentioning

confidence: 99%

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Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

et al. 2019

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Integrated vibration in electrical discharge machining (EDM) plays a key role in achieving high efficiency. High levels of variables can be employed in this approach due to integration. However, simultaneous optimization of the EDM parameters to achieve multi-objectives is still very complex and challenging. Studies on integrated vibration are still in a preliminary stage. This report addresses multi-objective optimization in EDM for SKD61 die steel using low-frequency vibration. MOORA (Multi-objective optimization based on ratio analysis) was chosen to resolve this multi-objective optimization problem. The material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were selected as performance measures in the EDM process. An analytical hierarchical process (AHP) was used to determine the weight value of the quality indicators. The results indicate that low-frequency vibrations significantly improve machining efficiency. When the frequency of the vibrations increased, MRR increased significantly such that MRR MAX = 64.48%. TWR and SR are smaller and their increase are given as TWR MAX = 20.3% and SR MAX = 18.47%. MOORA has been identified as a suitable alternative to multi-objective optimization in an EDM process using low-frequency vibrations for an assigned workpiece. The optimum parameters required to achieve the multi-objective were Ton = 25 ls, I = 8 A, Tof = 5.5 ls and F = 512 Hz, at the resultant quality criteria of MRR = 9.564 mm 3 /min, TWR = 1.944 mm 3 /min and SR = 3.24 lm with a maximum error of 8.24%.

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“…The exact optimal value is determined using Eq. (9). The accuracy of the calculation and experimental results are consistent and the largest calculation error is 8.24% (table 8).…”

Section: Effect Of Process Parameters On Zjsupporting

confidence: 60%

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

et al. 2019

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“…However, most micro-EDM systems are still designed for micro-holes drilling in industry applications. Low productivity of micro-holes drilling is still the main challenge for micro-EDM due to the significant tool wear and micro-tools fabrication [12,13]. To achieve mass-production of micro-hole fabrication, these two factors need to be addressed in this paper.…”

Section: Desktop Micro-edm Structurementioning

confidence: 99%

Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool

Huang

Sheu

2020

Micromachines

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Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15.

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“…Wong, Rahman, Lim, Han, and Ravi (2003) analysed the material removal mechanism of EDMM process using single pulse discharges and stated that high efficiency was obtained at lower energy levels. Lee, Kim, and Kim (2015) improved the efficiency of the EDMM process by vibrating the workpiece at low frequency and identified that the short circuits that occur during machining are reduced and proper flushing occurs due to low-frequency vibration. Guo et al (2014) analysed the material removal mechanism of the EDMM by integrating two temperature and molecular dynamics model.…”

Section: Literature Reviewmentioning

confidence: 99%

Tool speed and polarity effects in micro-EDM drilling of 316L stainless steel

Pilligrin

Asokan

Jerald

et al. 2017

Production & Manufacturing Research

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This paper focuses on the issues of Resistor-Capacitor-based Electrical Discharge Micro-Machining process and investigates the effects of tool speed and polarity on the performance measures such as Tool Wear Rate, Material Removal Rate, Overcut and Taper Angle by drilling on 316L Stainless Steel. Taguchi's L54 mixed orthogonal array design is employed to conduct experiments by varying tool polarity at two levels and voltage, capacitance, spindle speed at three levels. The cause and effect relationship between the experimental factors and responses are analysed and discussed using Factorial Analysis of Variance technique. Optimum combinations of machining parameters are also evaluated using Taguchi-based Grey Relational Analysis, by considering grey relational grade matrix and influence of process parameters on the responses. Further, microscopic analysis is done to identify the micro-voids, globular formation, and cracks present on the surface of the hole produced under various machining conditions.

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Effect of low frequency vibration on micro EDM drilling

Cited by 37 publications

References 19 publications

Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool

Tool speed and polarity effects in micro-EDM drilling of 316L stainless steel

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