共查询到20条相似文献,搜索用时 10 毫秒
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State of the art electrical discharge machining (EDM) 总被引:2,自引:0,他引:2
Electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult-to-machine by conventional machining processes. The non-contact machining technique has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests.In recent years, EDM researchers have explored a number of ways to improve the sparking efficiency including some unique experimental concepts that depart from the EDM traditional sparking phenomenon. Despite a range of different approaches, this new research shares the same objectives of achieving more efficient metal removal coupled with a reduction in tool wear and improved surface quality.This paper reviews the research work carried out from the inception to the development of die-sinking EDM within the past decade. It reports on the EDM research relating to improving performance measures, optimising the process variables, monitoring and control the sparking process, simplifying the electrode design and manufacture. A range of EDM applications are highlighted together with the development of hybrid machining processes. The final part of the paper discusses these developments and outlines the trends for future EDM research. 相似文献
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Development of Technology and Strategies for the Machining of Ceramic Components by Sinking and Milling EDM 总被引:3,自引:0,他引:3
This paper investigates the manufacturability of B4C, SiC, Si3N4-TiN by milling EDM and the performance of it has been compared to conventional sinking EDM. It is shown that due to the good flushing conditions, milling EDM performs well, even for the machining of ceramic materials with a rather low electrical conductivity (B4C, SiC). Because the used milling EDM technique removes material in a layer by layer fashion (2D-machining), a new strategy for the machining of complex 3D-shapes in ceramic material has been developed. It consists of a milling EDM pre-machining step, followed by one or more finishing sinking EDM steps. The developed strategy has been validated on an industrial example and compared to a pure sinking EDM strategy. Time reductions of more than 50% were obtained. 相似文献
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Advancing EDM through Fundamental Insight into the Process 总被引:6,自引:0,他引:6
This paper aims to show the prospects of electrical discharge machining (EDM) technology by interrelating recent achievements in fundamental studies on EDM with newly developed advanced application technologies. Although gap phenomena in EDM are very complicated and hence not yet very well understood, recent improvements in computers and electronic measuring instruments are contributing to new discoveries and inventions in EDM technology. Such newly acquired insight sometimes raises questions on the validity of the established theories of EDM phenomena, and EDM processes once believed to be impossible or unrealistic are now becoming practical. 相似文献
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An anodic tool polarity is generally adopted in sink electrical discharge machining (EDM) to maximize material removal relative to tool wear. Sink EDM of Ti and Ti6Al4V is however atypical in that these materials necessitate a cathodic tool polarity. Adding to the intrigue is γ-TiAl, which machines better under the conventional anodic polarity. This research focused on clarifying the phenomena behind this interesting behavior by investigating removal mechanisms over a range of relevant process conditions. The anomaly is demonstrated to arise from the polarity-dependent nature and extent of TiC formation on the work surface, which significantly affects material removal. 相似文献
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An extension to the electrical discharge machining method by introduction of radio-frequency plasma is proposed. Sparking with the radio-frequency plasma can be generated in paraffin oil by simple electrical circuitry. In this paper, experimental investigations are described on the fundamental effects of the resonant frequency, type of electrode and workpiece materials on machining characteristics for high performance radio-frequency machining in paraffin oil. The results show that the removal rate and the electrode wear vary with the resonant frequency and type of electrode materials. The surface roughness can be reduced to less than 1μm Rz under suitable experimental conditions. 相似文献
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This paper investigates the reliability of workpiece material removal per discharge (MRD) estimation for application in electrode wear compensation based on workpiece material removal. An experimental investigation involving discharge counting and automatic on the machine measurement of removed material volume was carried out in a range of process parameters settings from fine finishing to roughing. MRD showed a decreasing trend with the progress of the machining operation, reaching stabilization after a number of machined layers. Using the information on MRD and discharge counting, a material removal simulation tool was developed and validated. 相似文献
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This paper describes the heat source diameter of single pulse discharge in electrical discharge machining. To observe the discharge plasma, SiC and Ga2O3 single crystals were used as the electrode material since they are optically transparent and electrically conductive. It was found that plasma diameter expands within a few microseconds after dielectric breakdown and the plasma diameter is much larger than the discharge crater. From the measured diameter of the crater, the heat source diameter was obtained by solving the inverse problem of heat conduction analysis, and it was found that the heat source diameter is smaller than the plasma diameter but larger than the crater diameter. 相似文献
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Masahiro FujikiGap-Yong Kim Jun NiAlbert J. Shih 《International Journal of Machine Tools and Manufacture》2011,51(1):77-83
A new gap control strategy for five-axis milling using near-dry electrical discharge machining (EDM) has been experimentally investigated. The conventional EDM control strategy only allows the retraction of the electrode in the direction of machining trajectory, which results in inefficient gap control when the electrode is not perpendicular to the workpiece. The new gap controller is capable of retracting the electrode in the direction of its orientation. This enables more efficient enlargement of the discharge gap leading to faster recovery of average gap voltage. Experimental results show a 30% increase in material removal rate while the tool electrode wear ratio and surface roughness are not affected. Furthermore, EDM efficiency is improved due to the change in the electrode retraction in its axial direction. The gain tuning of the proposed controller is also discussed. This study shows the direction of electrode retraction is important for five-axis near-dry EDM milling. 相似文献
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Accumulation of machining debris due to inadequate gap flushing severely limits the material removal rate and impairs the quality of the machined surface in electrical discharge machining. This is particularly pronounced in electrical discharge drilling of holes with a high aspect-ratio, wherein conventional flushing techniques essentially cease to be effective. To this end, this paper proposes the application of novel tool electrodes comprising geometric features specifically designed to promote tool rotation-induced debris egress. The corresponding flow fields are modelled numerically to optimize said designs. Relative to conventional rotating cylindrical tools, removal rate enhancements on the order of 300% are demonstrated. 相似文献
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Flushing of the inter-electrode gap is of critical importance in the performance of electrical discharge sinking operations. When the provision of flushing holes in the tool or the workpiece is impractical, effective flushing is best realized by inducing a relative motion between the electrodes. This paper relates to a novel application inspired by the kinematics of a Reuleaux Triangle that facilitates flushing through synchronous orbiting of a rotating curvilinear tool. This innovative scheme enables the machining of regular as well as non-regular polygonal shapes with sharp corners. Experimental results from implementing this concept on a 4-axis CNC EDM machine tool are presented. 相似文献
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在分析玻璃刻花具体加工工艺的基础上,详细介绍了三维刀具半径补偿算法的实现。实践证明,通过配置旋转轴C轴,运用三维刀具补偿技术可以加工出复杂的花纹图案。 相似文献
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E. Ferraris V. Castiglioni F. Ceyssens M. Annoni B. Lauwers D. Reynaerts 《CIRP Annals》2013,62(1):191-194
This work presents an innovative method for the Electrical Discharge Drilling of ultra-high aspect ratio (AR > 30) micro holes. It makes use of tools insulated on the sidewall by means of a coating. The concept is to promote the process stability of micro EDM deep drilling by preventing secondary sparks. The performance of standard and customized tools is compared and reviewed against the main criteria of shape quality, tool wear and machining time. Process capabilities are also defined for a given coating. Micro holes within 0.2 mm in diameter and aspect ratio (AR) up to about 120 could be obtained within 1 h. A micro punching die is also realized by combining this strategy with micro wire EDM. 相似文献
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《Journal of Materials Processing Technology》2014,214(3):531-538
A novel compound machining of titanium alloy (Ti6Al4V) by super high speed electrical discharge machining (EDM) milling and arc machining was proposed in this paper. The power supply consisted of a pulse generator and a DC power source which were isolated from each other. A rotating pipe graphite electrode was connected to the negative pole of the power supply. The plasma channel was able to deionize, and maximum material removal rate (MRR) reached 21,494 mm3/min with a relative electrode wear ratio (REWR) of 1.7% because of high current and efficient flushing. Compared with traditional EDM, the compound machining achieved a significantly higher MRR but a similar REWR. To investigate the characteristics of the compound machining, the effects of electrode polarity, peak voltage, peak current, and flushing pressure on the performance of the process, including its MRR, REWR, and radius of overcut (ROC), were determined. In addition, scanning electron microscopy, X-ray diffraction, and microhardness analysis were conducted. Result shows that the proposed method can machine difficult-to-machine materials efficiently. 相似文献
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This paper describes the high speed EDM milling of 3D cavities using gas as the working fluid. In this new process, the molten workpiece material is removed and flushed out of the working gap with the help of high-pressure gas flow. The advantages or this technique are the remarkably small tool electrode wear and the significantly high material removal rate especially when oxygen gas is used due to the extremely strong oxidation of steel workpieces. Experiments showed that the material removal rate increases dramatically when the discharge power density on the wonting surface exceeds a certain threshold due to thermally activated chemical reaction between the gas and workpiece material. The maximum removal rate obtained was almost equal to that of high speed milling of quenched steel by a milling machine. The machining accuracy was considerably better when the gas was sucked through the pipe electrode than Jetted. 相似文献