A progress review in wire electrical discharge machining process

Balan, A.S.S.; Giridharan, Anandi

doi:10.15282/ijame.14.2.2017.1.0330

Cited by 11 publications

(8 citation statements)

References 125 publications

(200 reference statements)

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“…Based on the figure, when the wire tension is low the kerf width difference is at the peak (high). This is because the wire vibration is expected to reduce with the increment of wire tension that lead to the reduction of kerf width differences [3,29]. Besides that, the kerf width difference is at the highest when the gap voltage increases resulted in low dimensional accuracy of the machined slot.…”

Section: Studentized Residualsmentioning

confidence: 99%

See 1 more Smart Citation

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Ali¹,

Banu²,

Salehan³

et al. 2018

J. MECH. ENG. SCI.

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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.

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Section: Studentized Residualsmentioning

confidence: 99%

“…When higher wire tension is used, lower kerf can be achieved resulted in better accuracy since the wire vibration is less. Nevertheless, wire breakage tends to occur if the wire tension is too high [28][29].…”

Section: Introductionmentioning

confidence: 99%

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Ali¹,

Banu²,

Salehan³

et al. 2018

J. MECH. ENG. SCI.

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“…are significant for minor tolerances [7]. A review on the WEDM process by Balan et al [8] stated the factors such as Pulse on Time, Pulse off Time are much crucial for machining the Titanium alloy components.…”

Section: Introductionmentioning

confidence: 99%

Advantages of Taguchi Method compared to Response Surface Methodology for achieving the Best Surface Finish in Wire Electrical Discharge Machining (WEDM)

Kandala¹,

Solomon²,

Arulraj³

2022

JMechE

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Design of Experiments is a method to predict the optimum conditions of a process to reduce the time and number of experiments to be conducted with limited resources. In this paper, a comparative work on design and analysis of experiments between Taguchi method and response surface methodology is carried out in predicting the set of optimal conditions for obtaining the best surface roughness of commercially pure titanium powder metallurgy component using wire electrical discharge machining process. With surface roughness of the Titanium as the response and pulse on time, pulse off time, and sintering temperature of the wire electrical discharge machining process as the affecting factors, the optimum conditions for the surface roughness of the material have been predicted and analysed. Analysis of variance is used to identify the significant factors affecting the system. Both methods gave the same results and the Taguchi approach requires less number of experiments compared to response surface methodology and the predicted surface roughness of the components with the Taguchi method is 2.4 µm, whereas it is between 2.41-3.04 µm with the Response Surface Methodology. The factor Pulse on Time (N) shows a significant effect on the response of the system.

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“…Today, leading manufacturers of electroerosion equipment (GF Machining Solutions, Seibu Electric & Machinery Co., Ltd. and others) design their control systems based on the assessment of the critical current in the plasma breakdown. At high voltage, the feedback optimization system adjusts the feed rate and IEG [78][79][80][81]. Because controlling the amperage and voltage of the discharge pulses no longer provides a reliable estimate of the fraction of energy expended on interaction with contaminants, the real-time assessment of probabilities of short-circuiting and wire breakage loses accuracy, in turn leading to wire melting and breakage, thus significantly reducing the stability and productivity of WEDM.…”

Section: Introductionmentioning

confidence: 99%

“…Since poor heat dissipation during the processing of hard alloys may lead to a profound cumulative effect even if a small fraction of the pulses' energies is lost in removing and heating contaminants in the dielectric fluid [85], it is proposed that vibroacoustic emission signals be used as diagnostic parameters, thus allowing indirect determination Today, leading manufacturers of electroerosion equipment (GF Machining Solutions, Seibu Electric & Machinery Co., Ltd. and others) design their control systems based on the assessment of the critical current in the plasma breakdown. At high voltage, the feedback optimization system adjusts the feed rate and IEG [78][79][80][81]. Because controlling the amperage and voltage of the discharge pulses no longer provides a reliable estimate of the fraction of energy expended on interaction with contaminants, the real-time assessment of probabilities of short-circuiting and wire breakage loses accuracy, in turn leading to wire melting and breakage, thus significantly reducing the stability and productivity of WEDM.…”

Section: Introductionmentioning

confidence: 99%

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Grigoriev

Pivkin

Kozochkin

et al. 2021

Metals

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The field of applied wire electrical discharge machining (WEDM) is rapidly expanding due to rapidly increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co are advanced cutting materials widely used in industry due to the excellent combination of hardness and toughness, providing them obvious advantages over other cutting materials, such as cubic boron nitride, ceramics, diamond or high-speed steel. A rational choice of the WEDM modes is extremely important to ensure the dimensional quality of the manufactured cutting inserts, while roughness of the machined surface on the cutting edge is of great importance with regards to the application of wear-resistant coatings, which increases tool life. However, the stock control systems of CNC WEDM machines, which are based on assessment of electrical parameters such as amperage and voltage, are unable to timely detect conditions at which a threat of wire breakage appears and to prevent wire breakage by stopping the electrode feed and flushing out the interelectrode gap (IEG) when hard alloys with high heat resistance and low heat conductivity, such as WC, TiC and Co composites, are being machined, due to the inability to distinguish the working pulses and pulses that expend a part of their energy heating and removing electroerosion products contaminating the working zone. In this paper, the physicomechanical nature of the WEDM of hard alloy WC 88% + TiC 6% + Co 6% was investigated, and the possibility of using acoustic emission parameters for controlling WEDM stability and productivity were explored. Acoustic emission (AE) signals were recorded in octave bands with central frequencies of 1–3 and 10–20 kHz. It was found that at the initial moment, when the dielectric fluid is virtually free of contaminants, the amplitude of the high-frequency component of the VA signal has its highest value. However, as the contamination of the working zone by electroerosion products increases, the amplitude of the high-frequency component of the AE signal decreases while the low-frequency component increases in an octave of 1–3 kHz. By the time of the wire breakage, the amplitude of the high-frequency component in the octave of 10–20 kHz had reduced by more than 5-fold, the amplitude of the low-frequency component in the octave of 1–3 kHz had increased by more than 2-fold, and their ratio, coefficient Kf, decreased by 12-fold. To evaluate the efficiency of Kf as a diagnostic parameter, the quality of the surface being machined was investigated. The analysis of residual irregularities on the surface at the electrode breakage point showed the presence of deep cracks and craters typical of short-circuit machining. It was also found that the workpiece surface was full of deposits/sticks, whose chemical composition was identical to that of the wire material. The presence of the deposits evidenced heating and melting of the wire due to the increased concentration of contaminants causing short circuits. It was also shown that the wire breakage was accompanied by the “neck” formation, which indicated simultaneous impacts of the local heating of the wire material and tensile forces. Due to the elevated temperature, the mechanical properties the wire material are quickly declining, a “neck” is being formed, and, finally, the wire breaks. At the wire breakage point, sticks/deposits of the workpiece material and electroerosion products were clearly visible, which evidenced a partial loss of the pulses’ energy on heating the electroerosion products and electrodes. A further increase in the contamination level led to short circuits and subsequent breakage of the wire electrode. It was shown that in contrast to the conventional controlling scheme, which is based on the assessment of amperage and voltage only, the analysis of VA signals clearly indicates the risk of wire breakage due to contamination of the working zone, discharge localization and subsequent short circuits. The monotonic dependence of WEDM productivity on AE parameters provides the possibility of adaptive adjustment of the wire electrode feed rate to the highest WEDM productivity at a given contamination level. As the concentration of contaminants increases, the feed rate of the wire electrode should decrease until the critical value of the diagnostic parameter Kf, at which the feed stops and the IEG flushes out, is reached. The link between the AE signals and physicomechanical nature of the WEDM of advanced cutting materials with high heat resistance and low heat conductivity in different cutting modes clearly shows that the monitoring of AE signals can be used as a main or supplementary component of control systems for CNC WEDM machines.

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A progress review in wire electrical discharge machining process

Cited by 11 publications

References 125 publications

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

Advantages of Taguchi Method compared to Response Surface Methodology for achieving the Best Surface Finish in Wire Electrical Discharge Machining (WEDM)

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

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