Fundamental investigation of dry electrical discharge machining (DEDM) by optical emission spectroscopy and its numerical interpretation

Macedo, Felipe T.B.; Wiessner, Moritz; Hollenstein, Ch.; Esteves, Paulo Matheus Borges; Wegener, Konrad

doi:10.1007/s00170-016-9687-9

Cited by 19 publications

(17 citation statements)

References 40 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…distance between the electrodes (pd) as declared by the classical Paschen's law [10,[28][29][30][31][32][33][34]. However, in this situation, the gas pressure is essential since the airflow from the compressed air with 0.0345 MPa pressure assists in maintaining the ideal gap distance between the electrodes (workpiece and wire electrode).…”

Section: Dielectric Fluidmentioning

confidence: 99%

“…However, in this situation, the gas pressure is essential since the airflow from the compressed air with 0.0345 MPa pressure assists in maintaining the ideal gap distance between the electrodes (workpiece and wire electrode). The gap distance allows the phenomenon of breakdown voltage to occur which leads to the formation of microplasma [30,33,35]. Hence, compressed air as dielectric fluid would be the best choice for a stable machining since there is a continuous airflow with the 0.0345 MPa pressure at the machining area compared to the atmospheric air.…”

Section: Dielectric Fluidmentioning

confidence: 99%

“…In the DEDM process, it is essential to determine the pressure of gas during the machining process since it affects the formation of microplasma [30,33,35]. Figure 3 shows the graph of machining length with respect to gap voltage for dielectric fluid pressure.…”

Section: Dielectric Fluid Pressurementioning

confidence: 99%

“…3, when 0.0345 MPa dielectric fluid pressure is used, the machining process is much more stable (machining length ≥ 225 μm) with intact wire. It is due to the formation of the micro-breakdown mechanism which is influenced by the gap distance between the electrodes (d) as stated by the modified Paschen's law [28][29][30][31][32][33][34] (Subsection 3.1). When modified Paschen's law is applied in micro-breakdown mechanism, then ion-enhanced field emission plays a crucial role in generating the microplasma [10,28].…”

Section: Dielectric Fluid Pressurementioning

confidence: 99%

See 3 more Smart Citations

Stability of micro dry wire EDM: OFAT and DOE method

Banu

Ali

Rahman

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

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.

show abstract

Section: Dielectric Fluidmentioning

confidence: 99%

Section: Dielectric Fluidmentioning

confidence: 99%

Section: Dielectric Fluid Pressurementioning

confidence: 99%

Section: Dielectric Fluid Pressurementioning

confidence: 99%

See 2 more Smart Citations

Stability of micro dry wire EDM: OFAT and DOE method

Banu

Ali

Rahman

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Based on the Paschen's law, the breakdown of gas discharges are affected by the pressure and the gap distance between the tool electrode and the workpiece. The electrical discharge is produced due to high electric fields generated in the small gap distance [43]. Since the energy and the plasma pressure generated in gases are low [26], the wire vibration is also low which leads to better dimensional accuracy.…”

Section: Studentized Residualsmentioning

confidence: 99%

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Ali¹,

Banu²,

Salehan³

et al. 2018

J. MECH. ENG. SCI.

View full text Add to dashboard Cite

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.

show abstract