Proposing a new performance index to identify the effect of spark energy and pulse frequency simultaneously to achieve high machining performance in WEDM

ORIGINAL ARTICLE
First Online:
Received:
Accepted:
  • 161 Downloads

Abstract

Wire electrical discharge machining (WEDM) is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). WEDM demands high cutting rate and high quality to improve machining performance for manufacturing hard materials. The machining performance of computer-controlled WEDM is directly dependent on spark energy and pulse frequency parameters including discharge voltage, peak current, pulse duration, and charging time. In this paper, a new performance index to measure the effects of spark energy and pulse frequency on machining performance is proposed. Moreover, the effects of electric process parameters on performance measures including cutting speed, surface roughness, and white layer thickness are introduced.

Keywords

WEDM-CCM Spark energy Pulse frequency Duty factor Performance index 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Davim JP (2008) Machining fundamentals and recent advances. Springer, LondonGoogle Scholar
  2. 2.
    Muttamara A, Fukuzawa Y, Mohri N, Tani T (2003) Probability of precision micro-machining of insulating Si3N4 ceramics by EDM. J Mater Process Technol 140:243–247CrossRefGoogle Scholar
  3. 3.
    Wüthrich R, Fascio V (2005) Machining of non-conducting materials using electrochemical discharge phenomenon—an overview. Int J Mach Tools Manuf 45:1095–1108CrossRefGoogle Scholar
  4. 4.
    Maher I, Sarhan AAD, Hamdi M (2015) Review of improvements in wire electrode properties for longer working time and utilization in wire EDM machining. Int J Adv Manuf Technol 76:329–351CrossRefGoogle Scholar
  5. 5.
    Cheng X, Yang XH, Huang YM, Zheng GM, Li L (2014) Helical surface creation by wire electrical discharge machining for micro tools. Robot Comput Integr Manuf 30:287–294CrossRefGoogle Scholar
  6. 6.
    Maher I, Ling LH, Sarhan AAD, Hamdi M (2015) Improve wire EDM performance at different machining parameters—ANFIS modeling, 8th Vienna International Conference on Mathematical Modelling (MATHMOOD 2015), IFAC, Vienna University of technology, Vienna, Austria, pp. 105–110Google Scholar
  7. 7.
    Yeh C-C, Wu K-L, Lee J-W, Yan B-H (2013) Study on surface characteristics using phosphorous dielectric on wire electrical discharge machining of polycrystalline silicon. Int J Adv Manuf Technol 69:71–80CrossRefGoogle Scholar
  8. 8.
    Maher I, Sarhan AAD, Marashi H (2016) Effect of electrical discharge energy on white layer thickness of WEDM process, Reference Module in Materials Science and Materials Engineering, ElsevierGoogle Scholar
  9. 9.
    Yan M-T, Liu Y-T (2009) Design, analysis and experimental study of a high-frequency power supply for finish cut of wire-EDM. Int J Mach Tools Manuf 49:793–796CrossRefGoogle Scholar
  10. 10.
    Gökler Mİ, Ozanözgü AM (2000) Experimental investigation of effects of cutting parameters on surface roughness in the WEDM process. Int J Mach Tools Manuf 40:1831–1848CrossRefGoogle Scholar
  11. 11.
    El-Hofy H (2005) Advanced machining processes. McGraw-Hill, New YorkGoogle Scholar
  12. 12.
    Levy GN, Maggi F (1990) WED machinability comparison of different steel grades. CIRP Ann Manuf Technol 39:183–185CrossRefGoogle Scholar
  13. 13.
    Patil N, Brahmankar PK (2010) Determination of material removal rate in wire electro-discharge machining of metal matrix composites using dimensional analysis. Int J Adv Manuf Technol 51:599–610CrossRefGoogle Scholar
  14. 14.
    Liao YS, Yu YP (2004) Study of specific discharge energy in WEDM and its application. Int J Mach Tools Manuf 44:1373–1380CrossRefGoogle Scholar
  15. 15.
    Singh A, Ghosh A (1999) A thermo-electric model of material removal during electric discharge machining. Int J Mach Tools Manuf 39:669–682CrossRefGoogle Scholar
  16. 16.
    Cabanes I, Portillo E, Marcos M, Sánchez JA (2008) On-line prevention of wire breakage in wire electro-discharge machining. Robot Comput Integr Manuf 24:287–298CrossRefGoogle Scholar
  17. 17.
    Salah NB, Ghanem F, Atig KB (2006) Numerical study of thermal aspects of electric discharge machining process. Int J Mach Tools Manuf 46:908–911CrossRefGoogle Scholar
  18. 18.
    Izquierdo B, Sánchez JA, Plaza S, Pombo I, Ortega N (2009) A numerical model of the EDM process considering the effect of multiple discharges. Int J Mach Tools Manuf 49:220–229CrossRefGoogle Scholar
  19. 19.
    Dekeyser W, Snoeys R, Jennes M (1988) Expert system for wire cutting EDM, based on pulse classification and thermal modeling. Robot Comput Integr Manuf 4:219–224CrossRefGoogle Scholar
  20. 20.
    Lee C-S, Heo E-Y, Kim J-M, Choi I-H, Kim D-W Electrode wear estimation model for EDM drilling, Robotics and Computer-Integrated ManufacturingGoogle Scholar
  21. 21.
    Gostimirovic M, Kovac P, Sekulic M, Skoric B (2012) Influence of discharge energy on machining characteristics in EDM. J Mech Sci Technol 26:173–179CrossRefGoogle Scholar
  22. 22.
    Salonitis K, Stournaras A, Stavropoulos P, Chryssolouris G (2009) Thermal modeling of the material removal rate and surface roughness for die-sinking EDM. Int J Adv Manuf Technol 40:316–323CrossRefGoogle Scholar
  23. 23.
    Jahan M (2013) Micro-electrical discharge machining. In: Davim JP (ed) Nontraditional machining processes. Springer, LondonGoogle Scholar
  24. 24.
    Ferreira J (2007) A study of die helical thread cavity surface finish made by Cu-W electrodes with planetary EDM. Int J Adv Manuf Technol 34:1120–1132CrossRefGoogle Scholar
  25. 25.
    Portt J (1992) Introduction to wire EDM. John Portt, MichiganGoogle Scholar
  26. 26.
    Jameson EC (2001) Electrical discharge machining. Society of Manufacturing Engineers, Dearborn, MichiganGoogle Scholar
  27. 27.
    McGeough, J A (1988) Electrodischarge machining. In: Advanced methods of machining. Shapman and Hall, London, New YorkGoogle Scholar
  28. 28.
    Ramasawmy H, Blunt L, Rajurkar KP (2005) Investigation of the relationship between the white layer thickness and 3D surface texture parameters in the die sinking EDM process. Precis Eng 29:479–490CrossRefGoogle Scholar
  29. 29.
    Jangra K, Grover S, Aggarwal A (2011) Simultaneous optimization of material removal rate and surface roughness for WEDM of WC-Co composite using grey relational analysis along with Taguchi method. Int J Ind Eng Comput 2:479–490Google Scholar
  30. 30.
    Zipperian DC (2011) Metallographic handbook. PACE Technologies, ArizonaGoogle Scholar
  31. 31.
    Montgomery DC, Runger GC (2003) Applied statistics and probability for engineers, 3 ed., Wiley.Google Scholar

Copyright information

© Springer-Verlag London 2016

Authors and Affiliations

  1. 1.Department of Mechanical Engineering, Faculty of EngineeringKafrelsheikh UniversityKafrelsheikhEgypt
  2. 2.Centre of Advanced Manufacturing and Material Processing, Department of Mechanical Engineering, Faculty of EngineeringUniversity of MalayaKuala LumpurMalaysia
  3. 3.Department of Mechanical Engineering, Faculty of EngineeringAssiut UniversityAssiutEgypt

Personalised recommendations