Resource-Efficient Machining of Hard Metals

Kroening, Oliver; Herzig, Mathias; Schulze, H.‐P.; Hackert-Oschätzchen, Matthias; Kühn, Ralf; Zeidler, Henning; Schubert, Andreas

doi:10.4028/www.scientific.net/kem.611-612.708

Cited by 4 publications

(3 citation statements)

References 5 publications

(6 reference statements)

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“…Fig. 3: Simplified circuit diagram of the layout of the developed two-staged pulse generator with gap [4] The two-staged pulse generator consists of two voltage sources. They can be discerned by their purpose.…”

Section: Realization Of Ultra-short Pulses By a Two-staged Discharge ...mentioning

confidence: 99%

Micro Electrical Discharge Machining of Tungsten Carbide with Ultra-Short Pulse

Kröning¹,

Herzig²,

Hackert-Oschätzchen

et al. 2015

KEM

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Micro EDM (Electrical Discharge Machining) is a known nonconventional process for the machining of hard to cut materials. Due to its ablating nature based on melting and evaporation through heat induced by electrical discharges, it can function independently of the hardness, toughness or brittleness of the workpiece. Thus micro EDM is a possible process to fulfill the requirements of higher precision and high quality in carbide metal machining. Thereby the surface and the roughness of machined carbide metals depend on the discharge energy used. For machining carbide metals with high surface quality pulse generators with ultra-short discharges are required. This paper presents the development of a two-staged pulse generator with the ability to provide ultra-short pulses by using a two-staged pulse. The current and voltage signals of the discharges were recorded and their characteristics were analyzed.

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Section: Realization Of Ultra-short Pulses By a Two-staged Discharge ...mentioning

confidence: 99%

Micro Electrical Discharge Machining of Tungsten Carbide with Ultra-Short Pulse

Kröning¹,

Herzig²,

Hackert-Oschätzchen

et al. 2015

KEM

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“…A challenge is the production and processing of such structures. That is why we are investigating the processing parameters cutting of inhomogeneous metallic structures at this point by Wire -ECM [3,4] and Wire -EDM [5,6]. In this study, is used steel wool with a fiber thickness of 35 µm.…”

Section: Introductionmentioning

confidence: 99%

Special Features of the Non-Conventional Cutting (ECM, EDM) of Wool-Like Material Structures

Schulze¹,

Herzig²,

Kroening³

et al. 2022

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The non-conventional cutting of electrically conductive materials using WEDM and WECM and their hybrid processes is already standard in manufacturing technology. This is essentially based on homogeneous or layered materials. In the future, cellular, wool-like, or similarly structured materials will play a greater role and will be more important; especially the cutting in conjunction with homogeneous materials. In the study, experiments were carried out with a standard WEDM system and a WECM test system. In preliminary tests, various EC machine structures with different flushing and cutting directions have been tested, and because of the static wire arrangement, adjustments to a maximum working current have been tried out. Various feed speeds have been implemented for the test series and the influence of the wool structure on the regulation of the short circuits in the working gap has been analyzed. A modified equivalent circuit diagram has been created from the special features of the processing. The process regulation must be adapted to the special conditions of the spontaneous working gap reduction and thus the higher number of soft short circuits. The study should primarily show where the deviations of the WEDM and WECM from wool structures are; which changes have to be made, especially for process regulation. Secondarily, it was determined which cutting structures arise and whether the partial discharges have a marginal effect on the cutting result in both processes.

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“…In the field of hard turning, a large variety of empirical models have been put forward by various authors to analyze the effect of process parameters (cutting tool geometry, microstructure of work material, feed, depth of cut and speed), tool and workpiece characteristics on tool performance (tool wear, tool life and surface finish of machined surface) and so as to achieve optimum machining conditions for various grades of hardened steel during its hard turning. 16–18 The influence of machining conditions on cutting forces and roughness of the machined surface was investigated during finish machining of hardened steel (MDN 250) using ceramic tool through RSM. 19 The best fit was described by a linear model for cutting forces, and the significant contributing factors were the depth of cut and feed.…”

Section: Introductionmentioning

confidence: 99%

A review of empirical modeling techniques to optimize machining parameters for hard turning applications

Dureja

Gupta

Sharma

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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There has been a tremendous development in the field of modeling and optimization methods starting from Taylor’s tool life model. Use of costly tools such as polycrystalline cubic boron nitride, polycrystalline diamond and ceramics in high-end computer numerical control machining forces the researcher to minimize the experimental runs to achieve the best cutting conditions with minimum tool wear and overall production cost. Machining process optimization to achieve said objectives comprises selecting optimum cutting parameters by applying low-cost mathematical models. This article attempts to evaluate the applicability of various modeling and optimization methods to specific response parameters in hard turning problems. Various empirical modeling techniques such as linear regression modeling, artificial neural networks, polynomial and fuzzy modeling along with process optimization through Taguchi, response surface methodology and genetic algorithm for hard turning applications have been discussed in length to provide the production engineers a ready database to compare relative merits and suitability of these techniques for a particular machining application. Also, article discusses integration of different modeling and optimization techniques to achieve desired goals when a single optimization technique is not able to provide the acceptable solution. The last part of the article highlights the current trends in hard turning applications and research priorities for future work.

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Resource-Efficient Machining of Hard Metals

Cited by 4 publications

References 5 publications

Micro Electrical Discharge Machining of Tungsten Carbide with Ultra-Short Pulse

Micro Electrical Discharge Machining of Tungsten Carbide with Ultra-Short Pulse

Special Features of the Non-Conventional Cutting (ECM, EDM) of Wool-Like Material Structures

A review of empirical modeling techniques to optimize machining parameters for hard turning applications

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