Length-wise tool wear compensation for micro electric discharge drilling of blind holes

Malayath, Ganesh; Katta, Srikanth; Sidpara, Ajay; Deb, Sankha

doi:10.1016/j.measurement.2018.12.047

Cited by 15 publications

(3 citation statements)

References 25 publications

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“…A maximum machining depth error of 6% was observed using the proposed tool electrode wear compensation method. Ganesh et al [20] proposed a new tool wear compensation method that integrated the micro-EDM machine to an image processing module and computer-controlled tool wear prediction algorithm. Deviation of less than 1% between the actual depth and the expected depth of the micro-hole can be obtained by the proposed novel method.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

Gou

Lai²,

Lin³

et al. 2022

Preprint

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The accumulation of debris in the inter-electrode gap caused by inefficient flushing during the micro-electrical discharge machining (micro-EDM) process leads to severe tool electrode wear and decreases the machining accuracy of micro-holes. In this study, a novel method of tool electrode spiral motion feed mode combined with fixed reference axial compensation (FRAC) is proposed to promote the evacuation of debris and improve the machining accuracy of micro-holes. Different depths of micro-holes in titanium alloy are drilled using the tool electrode linear feed mode and tool electrode spiral motion feed mode combined with FRAC and without compensation. The process parameters are optimized and determined by means of response-surface experiments. The results show that the tool electrode spiral motion feed mode can improve the debris evacuation more effectively than the tool electrode linear feed mode. The micro-hole without a cone at the bottom can be fabricated using the tool electrode spiral motion feed mode. The introduction of FRAC method can improve the depth error of micro-holes further. A high accuracy micro-hole with a depth error of only 0.21% can be fabricated efficiently under the optimal process parameters. The tool electrode spiral motion feed mode combined with FRAC has an obvious advantage in the fabrication of high accuracy micro-holes during the micro-EDM process.

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Section: Introductionmentioning

confidence: 99%

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

Gou

Lai²,

Lin³

et al. 2022

Preprint

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“…The general improvements of the EDD responses are around 59%. A new measurement is proposed to explore the TW of the drilled hole [25]. The error of 1% revealed the effectiveness of the measuring method.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Electrical Discharge Drilling Process of SS304 for Energy Efficiency, Product Quality, and Productivity

2020

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The electrical discharge drilling (EDD) process is an effective machining approach to produce various holes in difficult-to-cut materials. However, the energy efficiency of the EDD operation has not thoroughly been considered in published works. The aim of the current work is to optimize varied parameters for enhancing the material removal rate (MRR), saving drilled energy (ED), and decreasing the expansion of the hole (HE) for the EDD process. Three advanced factors, including the gap voltage adjustor (GAP), capacitance parallel connection (CAP), and servo sensitivity selection (SV), are considered. The predictive models of the performances were proposed with the support of the adaptive neuro-based fuzzy inference system (ANFIS). An integrative approach combining the analytic hierarchy process (AHP) and the neighborhood cultivation genetic algorithm (NCGA) was employed to select optimal factors. The findings revealed the optimal values of the CAP, GAP, and SV were 6, 5, and 4, respectively. Moreover, the ED and HE were decreased by 16.78% and 28.68%, while the MRR was enhanced by 89.72%, respectively, as compared to the common setting values. The explored outcome can be employed as a technical solution to enhance the energy efficiency, drilled quality, and productivity of the EDD operation.

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“…The dynamics of drilling tools plays a significant role in cutting force, chatter stability and quality. The pre-twisted geometry of the flute section contributes to the coupling of torsional-axial vibrations of the drilling tool [2]. When the torsional load is applied on the drilling tool and results into displacements in axial direction.…”

Section: Introductionmentioning

confidence: 99%

Stability Analysis of a Two Degree of Freedom Micro-drilling Model

Zhang¹,

Wang²,

Cao³

et al. 2020

dtetr

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This paper introduces the assembly system model of drilling tool, drilling tool and fixture. In this system, the failure of drilling tools is caused by self-excited vibration, that is, the self-excited vibration of components in the axial direction. In this paper, the stable lobes of rock macro and micro drilling are established, the deep well rotary drilling system is analyzed in detail, the influence of changing the axial damping coefficient on the critical speed of drilling in macro and micro drilling is investigated, and the flutter behavior in the process of drilling is considered comprehensively, so as to avoid tool flutter damage and workpiece scrap and improve productivity.

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Length-wise tool wear compensation for micro electric discharge drilling of blind holes

Cited by 15 publications

References 25 publications

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

Fabrication of high accuracy micro-hole by micro-EDM under tool electrode spiral motion feed mode aided with fixed reference axial compensation

Multi-Response Optimization of Electrical Discharge Drilling Process of SS304 for Energy Efficiency, Product Quality, and Productivity

Stability Analysis of a Two Degree of Freedom Micro-drilling Model

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