Using wire electrical discharge machining for improved corner cutting accuracy of thin parts

Dodun, Oana; Gonçalves-Coelho, António; Slătineanu, Laurenţiu; Nagîţ, Gheorghe

doi:10.1007/s00170-008-1531-4

Cited by 43 publications

(20 citation statements)

References 18 publications

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“…Based on multiple studies, it has been proven that the inappropriate combination of process parameter settings negatively impacts geometrical accuracy. Dodun et al [8], when examining errors in geometrical accuracy at machining a small corner angle in thin portions, consider also a modification of MTP (peak current, discharge pulse on-time and off-time duration, etc.). This adjustment, of course, also leads to a reduction of the wire electrode speed, and thus, to a reduction in its vibration.…”

Section: Introductionmentioning

confidence: 99%

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

Straka

Čorný

Piteľ

2017

Metals

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Abstract:The geometrical accuracy of the machined surface can generally be understood mainly as accuracy of shape, orientation, position and run-out. As a general rule; it is quantified by the corresponding deviations from the nominal area. The size of the geometric deviation from the nominal area may in practice affect the conventionally measured value of the dimension, even if the required dimensional tolerance is adhered to. Since electro-erosive machining technology belongs to very precise finishing technologies; even the small geometrical accuracy deviation has a negative impact on the resulting quality of machined surfaces. The aim of the experiments was to contribute to the knowledge database, which defines the influence of the process parameters at electrical discharge machining with the CuZn37 tool electrode on errors of geometrical accuracy of the machined surface. On the basis of the results of the experimental measurements, graphical dependencies were determined which predict geometrical accuracy of the machined surface in terms of the maximum deviation of flatness after electrical discharge machining of tool steel EN X30WCrV9-3 (W.-Nr. 1.2581) with CuZn37 wire electrode of 0.20 mm diameter to determine the appropriate combination of process parameters.

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Section: Introductionmentioning

confidence: 99%

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

Straka

Čorný

Piteľ

2017

Metals

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“…They also set up a geometrical model of the wire electrode path and numerical control (NC) path before investigating the relationship between the wire electrode movement and NC movement. Dodun et al [11] investigated the WEDM corner cutting accuracy. Their experimental work shows that the use of WEDM to obtain outside corners with a small corner angle and small thickness produces a machining error shaped like post-yield bending.…”

Section: Introductionmentioning

confidence: 99%

Optimization of wire electrical discharge machining process parameters for cutting tungsten

Yang

Tzeng

Yang

et al. 2011

Int J Adv Manuf Technol

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This study analyzes variations in metal removal rate (MRR) and quality performance of roughness average (R a ) and corner deviation (CD) depending on parameters of wire electrical discharge machining (WEDM) process in relation to the cutting of pure tungsten profiles. A hybrid method including response surface methodology (RSM) and back-propagation neural network (BPNN) integrated simulated annealing algorithm (SAA) were proposed to determine an optimal parameter setting. The results of 18 experimental runs via a Taguchi orthogonal table were utilized to train the BPNN to predict the MRR, R a , and CD properties. Simultaneously, RSM and SAA approaches were individually applied to search for an optimal setting. In addition, analysis of variance was implemented to identify significant factors for the processing parameters. Furthermore, the field-emission scanning electron microscope images show that a lot of built-edge layers were presented on the finishing surface after the WEDM process. Finally, the optimized result of BPNN with integrated SAA was compared with that obtained by an RSM approach. Comparisons of the results of the algorithms and confirmation experiments show that both RSM and BPNN/SAA methods are effective tools for the optimization of parameters in WEDM process.

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“…However, reducing the conductivity of the water means that the machine filtration system may need additional maintenance which adds to the overall measurement cost. Reducing the pulse duration as well as the current have been shown to give improved surface roughness [12], but only for machining by multiple cuts: no literature is available on the potential improvement obtained during a single cut as required for the contour method.…”

Section: Introductionmentioning

confidence: 99%

“…Vibration and deflection of the wire, as well as spark intensity variations, are the main sources of dimensional inaccuracy of machined parts. Bending of the wire near the workpiece edges is often considered to be a cause of scatter in measured data, and as a remedy it is suggested to increase the wire tension [12].…”

Section: Introductionmentioning

confidence: 99%

Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

Ahmad

Fitzpatrick

2015

Metall Mater Trans A

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The contour method of residual stress measurement relies on the careful application of wire electro-discharge machining (WEDM) for the cutting stage. Changes in material removal rates during the cut lead to errors in the final calculated values of residual stress. In this study WEDM cutting parameters have been explored to identify the optimum conditions for contour method residual stress measurements. The influence of machine parameters on the surface roughness and cutting artefact of the contour cut are discussed. It has been identified that the critical parameter in improving the surface finish is the spark pulse duration. A typical cutting artefact and its impact on measured stress values has been identified and demonstrated for a contour cut in a welded marine steel. A procedure is presented to correct contour displacement data from the influence of WEDM cutting artefacts, and is demonstrated on the correction of a measured weld residual stress. The corrected contour method improved the residual stress magnitude up to 150 MPa. The corrected contour method results were validated by X-ray diffraction, incremental centre hole drilling and neutron diffraction.

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Using wire electrical discharge machining for improved corner cutting accuracy of thin parts

Cited by 43 publications

References 18 publications

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

Optimization of wire electrical discharge machining process parameters for cutting tungsten

Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

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