Study on Micro-machining by Micro-WEDM

Di, Shichun; Huang, Ruining; Chi, Guanxin

doi:10.1109/nems.2006.334857

Cited by 21 publications

(9 citation statements)

References 7 publications

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“…The literature review highlights that there is insufficient work on the analysis and optimization of the surface finish of the miniature gears manufactured by WEDM and the modeling and optimization of the same by ANN. Di et al 12 used WEDM to manufacture miniature gears of 40 mm module, having seven teeth, from 1-mm-thick stainless steel plate and achieved average surface roughness less than 0.1 mm. Ali et al 13 manufactured external spur gear of 3.58 mm diameter with 17 teeth from a 6-mm-thick beryllium-copper blank using WEDM and highlighted the role of combination of low discharge energy parameters to produce gears with better surface finish.…”

Section: Introductionmentioning

confidence: 99%

Analysis and optimization of surface finish of wire electrical discharge machined miniature gears

Gupta

Jain

2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article reports about analysis and optimization of surface roughness parameters (i.e. average roughness Ra and maximum roughness Rt) of wire electrical discharge machined fine-pitch miniature spur gears made of brass. Effects of four wire electrical discharge machining process parameters (i.e. voltage, pulse-on time, pulse-off time and wire feed rate) on the surface roughness parameters of the miniature gears were studied by conducting 29 experiments with two replicates each and designed based on Box–Behnken approach of response surface methodology. Analysis of variance study found all four input parameters to be significant. Experimentally, the surface roughness has been found to increase with higher voltage and longer pulse-on time and decrease with longer pulse-off time and higher wire feed rate. Desirability analysis was used to optimize the wire electrical discharge machining parameters, so as to minimize the Ra and Rt simultaneously. Optimum values of Ra and Rt obtained from the confirmation experiments conducted at the optimized wire electrical discharge machining parameters are superior than the values reported in the literature. Artificial neural network model has been developed for prediction of the surface roughness of the wire electrical discharge machined miniature gears. Very close agreement was found among the surface roughness values predicted by response surface methodology and artificial neural network with the corresponding experimental values.

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Section: Introductionmentioning

confidence: 99%

Analysis and optimization of surface finish of wire electrical discharge machined miniature gears

Gupta

Jain

2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…They concluded that the electrode diameter was the most significant parameter that affected accuracy. Di et al [11] manufactured stainless steel microinternal gears of 100-μm module with seven teeth and 1-mm thickness by micro-WSEM using a tungsten wire of 30-μm diameter and at a speed of 20 mm/min. The best fabricated gear achieved ±0.2-μm accuracy, 0.1-μm surface roughness and 2-μm-thick recast layer.…”

Section: Wsem Of Gearsmentioning

confidence: 99%

“…All these techniques have inherent strengths and weaknesses. Lithography, embossing and electroforming are complex, expensive and not suitable for all material types [7,11,12]. Hobbing, stamping, die casting, extrusion and powder metallurgy produce poor-quality results initially that usually require finishing operations such as grinding, lapping, honing, etc.…”

Section: Introductionmentioning

confidence: 99%

Spark erosion machining of miniature gears: a critical review

Gupta

Jain

Laubscher

2015

Int J Adv Manuf Technol

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This paper presents a review of previous work conducted as regards to the machining of miniature gears by spark erosion machining (SEM) process and its variants. Miniature gears are key components of various small devices. Their proper function requires the selection of an appropriate manufacturing and/or finishing process that will deliver the required fit for purpose quality. Sparkerosion-based machining processes have a proven track record to impart the relevant quality characteristics and to minimize the number of operations required. This paper commences with an introduction to miniature gears before outlining the spark erosion machining of gears. Details as regards to previous efforts conducted on machining of these gears by SEM-based processes are presented before selected future research trends, directions and avenues for possible future research are offered. This paper focuses exclusively on SEM of miniature gears even though it is noted that similar research work on macrogears is also limited. This review paper aims to facilitate an overall view of all the available literature on spark erosion machining of miniature gears in a single article, to promote the technology and to provide a road map to researchers for making efforts towards exploring these technologies further.

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“…Among various miniature parts, gear is one of the most common components used in micro and nano-electromechanical devices such as watches, micro-turbines/pumps, harmonic drives, instruments used in dental procedures, and medical devices, micro-motors, precision measuring instruments, electronic appliances, and so on. 1 However, conventional manufacturing methods are not suitable for producing such types of parts. Non-traditional machining method such as wire electro-discharge machining (EDM) is used to manufacture such products made of difficult-to-machined alloys/materials.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

Chaudhary

Siddiquee

Chanda³

et al. 2020

Advances in Mechanical Engineering

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Generally, gear is an essential component in various electro-mechanical devices, but its manufacturing at the micro-level is challenging. The non-conventional manufacturing processes, such as electro-discharge machining (EDM), is suitable in gear fabrication. Although miniature gears have strict accuracy requirements, the optimization of the EDM process parameters, especially for advanced materials and alloys, is critical. In this paper, Nimonic alloy miniature gears are manufactured using wire-EDM and the effect of process parameters, such as peak current, pulse-off (POFF) time, pulse-on (PON) time, wire tension, and dielectric fluid on the response factors are analyzed. The primary response factors, such as surface roughness, machining time, material removal rate, kerf width (KW), surface microhardness, and depth of microhardness are considered. Also, different dielectric fluids are prepared, which include ethylene glycol mixed demineralized water, oxygen mixed demineralized water, ethylene glycol and alumina powder mixed demineralized water, and ethylene glycol alumina powder and oxygen mixed demineralized water. Furthermore, the effect of process parameters on the multi-response using Pareto ANOVA has been analyzed. The results demonstrate that ethylene glycol mixed demineralized water, as a dielectric fluid, is the most influencing parameter to reduce the surface roughness, machining time, KW, and improve micro-hardness. Thus, dielectric fluid is an essential factor obtained from multi-response optimization followed by peak current, POFF time, wire tension, and PON time.

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Study on Micro-machining by Micro-WEDM

Cited by 21 publications

References 7 publications

Analysis and optimization of surface finish of wire electrical discharge machined miniature gears

Analysis and optimization of surface finish of wire electrical discharge machined miniature gears

Spark erosion machining of miniature gears: a critical review

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

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