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Page 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.

Authors:

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

Published Date:

April 7th, 2010

Presented by:

Mark Sydenham

Page 2: 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.

References[1] Ho K H and Newman S T 2003 State of the art electrical

discharge machining (EDM) Int. J. Mach. Tools Manuf. 43 1287–300

[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. 140 318–25

[3] Pham D T, Dimov S S, Bigot S, Ivanov A and Popov K 2004 Micro EDM—recent developments and research issues J. Mater. Process. Technol. 149 0–7

[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. 55 643–66

[5] Masuzawa T 2000 State of the art of micromachining CIRP Ann. Manuf. Technol. 49 473–88

[6] Masuzawa T and Tonshoff H K 1997 Three-dimensional micromachining by machine tools CIRP Ann. Manuf. Technol. 46 621–8

[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. 51 157–60

[8] Alting L, Kimura F, Hansec H N and Bissacco G 2003 Micro engineering CIRP Ann. Manuf. Technol. 52 635–57

[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 7–12

[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. 49 451–72

[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 1065–73

[12] Bleys P, Kruth J P and Lauwers B 2004 Sensing and compensation of tool wear in milling EDM J. Mater. Process. Technol. 149 139–46

[13] Yu Z Y, Masuzawa T and Fujino M 1998 Micro-EDM for three-dimensional cavities—development of uniform wear method CIRP Ann. Manuf. Technol. 47 169–72

[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. 164–165 889–96

[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 75–82

[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 355–8

[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. 18 897–905

[18] Rajurkar K P and Yu Z Y 2000 3D micro-EDM using CAD/CAM CIRP Ann. Manuf. Technol. 49 127–30 [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 233–8

[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) 1–6 (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 20–3 (in Chinese)

[22] Yu Z Y, Kozak J and Rajurkar P K 2003 Modeling and simulation of micro EDM process CIRP Ann. Manuf. Technol. 52 143–6

Page 3: 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.

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

Page 4: 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.

Background information on the Electric Discharge Machining Process

Page 5: 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.

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.

Page 6: 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.

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.

Page 7: 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.

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

Page 8: 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.

Design Parameters

∆Z = Tool Feed (∆Z = Lw + Le)

Lw = The average machined depth of one layer

Le = Electrode wear length

R = volumetric relative wear ratio Sw = cross sectional area of the

cavity Se = cross sectional area of the

electrode N = number of compensation times

where:

Page 9: 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.

Experimental EquipmentMachine Setup Cut Shape and Tool Path

Page 10: 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.

Results

Page 11: 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.

More Results

Notice the difference in the measurement range. Left side range (UWM): 2.80 µm Right side range (CLU): 2.58 µm

Page 12: 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.

Results Summary

UWMLower material removal rateHigher surface roughness

CLUHigher material removal rateLower surface roughness

Page 13: 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.

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.

Page 14: 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.

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.

Page 15: 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.

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.

Page 16: 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.

Pop Quiz

How long did it take to EDM the shape in the picture below?

Page 17: 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.

Answer

16 hours and 8 minutes


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