Micro dry wire electrical discharge machining (μDWEDM) is a process where gas is used as the dielectric fluid instead of a liquid. In this process , certain modifications of wire electrical discharge machining (WEDM) are needed during the machining operation to achieve stable machining. Smooth and stable machining operation in μDWEDM process remains as a critical issue. Thus, this paper presents the investigation of process parameters for a stable μDWEDM process. The investigation was performed on a stainless steel (SS304) with a tungsten wire as the electrode using integrated multi-process machine tool, DT 110 (Mikrotools Inc., Singapore). View all related documents based on references
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.
Micro dry wire EDM is a process where gas is used as the dielectric fluid instead of a liquid. In this process certain modifications of a wire EDM are needed during the machining operation to achieve stable machining. Optimizing kerf to get high dimensional accuracy is one of the critical issues in micro dry wire EDM. The fundamental modelling for optimum kerf using micro dry wire EDM has not been formulated yet. Due to the complex phenomenon, the prediction of optimum kerf in a micro dry wire EDM process is rather difficult. Hence, the main objectives of this research are to improve the micro dry wire EDM process and to develop mathematical models for optimum kerf using micro dry wire EDM. During the process improvement of micro dry wire EDM, various machining setup will be involve in order to achieve the most stable process. The most stable machining process will be used to prove the developed mathematical models. A mathematical relationship between kerf and process parameters is anticipated. The mathematical models in conjunction with experimental data will eventually produce the desired theory. The developed process and mathematical model of kerf is a breakthrough in fabricating products such as micro tools, molds etc. with optimum kerf and high dimensional accuracy. The successful completion of this research will contribute to the environmental friendly micromachining process.
Abstract.Painting is an important process in the automotive assembly to give more attractive appearance to the vehicles and to provide the layer of protection against corrosion and weathering. The objective of this paper is to identify and analyze the factors affecting the quality of painting process at Company RST's Paint Shop. The paint shop was unable to perform the painting process satisfactorily and deliver the painted vehicle bodies as per customer specifications. The study concentrated on the fiber defect detected at Top Coat Area as the major problem of paint deficiency. Using activities like Genba investigation, data collection, trials and data analysis, the root causes of the problem were identified. Six Sigma DMAIC approach was utilized in conducting the improvement activities. Through designed experiments conducted to determine the best parameter setting of the spray gun used in the painting process, it was found that 3.5 bars for air pressure and 450 ml/minutes for fluid delivery resulted in the lowest paint defect. The use of Six Sigma DMAIC approach had succeeded in helping the company to minimize paint fiber defect per unit (DPU) from 10 to less than 3 DPU. The results from the study have provided an insight on successful deployment of DMAIC through application of its various statistical tools and techniques, and as the systematic problem-solving framework on solving actual industrial issues such as automotive painting problem.
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