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Authors: Hui-Lan Yu, Ji-Jie Luan, Jian-Zhong Li, Yu-Sheng Zhang, Zu-Yuan Yu and Dong-Ming Guo...

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  • Slide 1
  • Authors: Hui-Lan Yu, Ji-Jie Luan, Jian-Zhong Li, Yu-Sheng Zhang, Zu-Yuan Yu and Dong-Ming Guo Published Date: April 7 th, 2010 Presented by: Mark Sydenham
  • Slide 2
  • References [1] Ho K H and Newman S T 2003 State of the art electrical discharge machining (EDM) Int. J. Mach. Tools Manuf. 43 1287300 [2] Lim H S, Wong Y S, Rahman M and Edwin Lee M K 2003 A study on the machining of high-aspect ratio micro- structures using micro-EDM J. Mater. Process. Technol. 140 31825 [3] Pham D T, Dimov S S, Bigot S, Ivanov A and Popov K 2004 Micro EDMrecent developments and research issues J. Mater. Process. Technol. 149 07 [4] Rajurkar K P, Levy G, Malshe A, Sundaram M M, McGeough J, Hu X, Resnick R and DeSilva A 2006 Micro and nano by electro-physical and chemical processes CIRP Ann. Manuf. Technol. 55 64366 [5] Masuzawa T 2000 State of the art of micromachining CIRP Ann. Manuf. Technol. 49 47388 [6] Masuzawa T and Tonshoff H K 1997 Three-dimensional micromachining by machine tools CIRP Ann. Manuf. Technol. 46 6218 [7] Bleys P, Kruth J P, Lauwers B, Zryd A, Delpretti R and Tricarico C 2002 Real-time tool wear compensation in milling EDM CIRP Ann. Manuf. Technol. 51 15760 [8] Alting L, Kimura F, Hansec H N and Bissacco G 2003 Micro engineering CIRP Ann. Manuf. Technol. 52 63557 [9] Yu Z Y, Masuzawa T and Fujino M 1998 3D micro-EDM with simple shape electrode, part 1: machining of cavities with sharp corners and electrode wear compensation Int. J. Electr. Mach. 3 712 [10] Van Brussel H, Peirs J, Reynaerts D, Delchambre A, Reinhart G, Roth N, Weck M and Zussman E 2000 Assembly of microsystems CIRP Ann. Manuf. Technol. 49 45172 [11] Yan M T, Huang K Y and Lo C Y 2009 A study on electrode wear sensing and compensation in micro-EDM using machine vision system Int. J. Adv. Manuf. Technol. 42 106573 [12] Bleys P, Kruth J P and Lauwers B 2004 Sensing and compensation of tool wear in milling EDM J. Mater. Process. Technol. 149 13946 [13] Yu Z Y, Masuzawa T and Fujino M 1998 Micro-EDM for three- dimensional cavitiesdevelopment of uniform wear method CIRP Ann. Manuf. Technol. 47 16972 [14] Luis C J, Puertas I and Villa G 2005 Material removal rate and electrode wear study on the EDM of silicon carbide J. Mater. Process. Technol. 164165 88996 [15] Narasimhan J, Yu Z Y and Rajurkar K P 2005 Tool wear compensation and path generation in micro and macro EDM J. Manuf. Process. 7 7582 [16] Bigot S, Ivanov A and Popov K 2005 A study of the micro EDM electrode wear Proc. 1st Int. Conf. on Multi-Material Micro Manufacture pp 3558 [17] Sanchez J A, Cabanes I, Lopez de Lacalle L N and Iamikiz A 2001 Development of optimum electrodischarge machining technology for advanced ceramics Int. J. Adv. Manuf. Technol. 18 897905 [18] Rajurkar K P and Yu Z Y 2000 3D micro-EDM using CAD/CAM CIRP Ann. Manuf. Technol. 49 12730 [19] Yu Z Y and Rajurkar K P 2000 Generation of complex micro cavities by micro EDM Trans. North American Manufacturing Research Institution of SME28 2338 [20] Yuzawa T, Magara T, Goto A, Lmai Y, Sato T and Yiyo T 1995 Micro contour EDM machining using thin cylindrical electrode Denki Kako Gijutsu 19 (63) 16 (in Japanese) [21] Deng R, Wu P, Pei J Y, Guo C N and Hu D J 2007 Study of compensation in micro-EDM Electromachining Mould 4 203 (in Chinese) [22] Yu Z Y, Kozak J and Rajurkar P K 2003 Modeling and simulation of micro EDM process CIRP Ann. Manuf. Technol. 52 1436
  • Slide 3
  • Function of Paper In the context of EDM micromachining: Present electrode wear compensation methods described in previous research papers Present new method of electrode wear compensation Compare new method to other methods
  • Slide 4
  • Background information on the Electric Discharge Machining Process
  • Slide 5
  • Why is electrode wear compensation important? As discussed in class, tool wear directly effects the tolerances of the part being machined. Smaller parts with tight tolerances need to be machined with special emphasis placed on tool wear.
  • Slide 6
  • Previously Proposed Methods Linear Compensation Method (LCM) Electrode is moved down a unit distance every unit length according to the wear rate of the electrode Is flawed because it assumes the tool only wears on the bottom when it actually wears the sides as well Uniform Wear Method (UWM) Tool path is designed with certain UWM rules that create a condition in which only the bottom of the tool wears Tool plunges at the beginning of a pass to compensate for tool wear Is flawed because plunging the tool causes unstable machining and poor surface finish VS.
  • Slide 7
  • The Design Principle of CLU Combination Linear Uniform (CLU) Tool path follows UWM rules to ensure tool wear occurs only on the bottom of the tool The tool is incremented down during the pass as described in the LCM Tool wear is compensated for in the tool path using CAD/CAM software (as shown to the left) By combining both methods and with the new assistance of a CAM program, the authors hope to more accurately account for the tool wear
  • Slide 8
  • Design Parameters Z = Tool Feed (Z = L w + L e ) L w = The average machined depth of one layer L e = Electrode wear length R = volumetric relative wear ratio S w = cross sectional area of the cavity S e = cross sectional area of the electrode N = number of compensation times where:
  • Slide 9
  • Experimental Equipment Machine SetupCut Shape and Tool Path
  • Slide 10
  • Results
  • Slide 11
  • More Results Notice the difference in the measurement range. Left side range (UWM): 2.80 m Right side range (CLU): 2.58 m
  • Slide 12
  • Results Summary UWM Lower material removal rate Higher surface roughness CLU Higher material removal rate Lower surface roughness
  • Slide 13
  • Technical advancement? Based on the results, there is a benefit in using CLU over UWM or LCM to compensate for electrode wear in micro EDM.
  • Slide 14
  • Is this advancement practical for industrial use? There is the potential for this study to benefit industry but this is not discussed in the research paper.
  • Slide 15
  • Which industries would benefit from this study? Specific industries are not described in the research paper However, the paper does mention that micro EDM is used to machine micro parts, dies and molds.
  • Slide 16
  • Pop Quiz How long did it take to EDM the shape in the picture below?
  • Slide 17
  • Answer 16 hours and 8 minutes
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