Volume 19, Issue 6 (June 2019)                   Modares Mechanical Engineering 2019, 19(6): 1519-1528 | Back to browse issues page

XML Persian Abstract Print


Download citation:
BibTeX | RIS | EndNote | Medlars | ProCite | Reference Manager | RefWorks
Send citation to:

Abyar Firouzabadi H, Abdullah A. WEDM Errors in Straight and Arced Paths: Analysis of Spark Angles on the Roughing and Finishing Stages. Modares Mechanical Engineering 2019; 19 (6) :1519-1528
URL: http://mme.modares.ac.ir/article-15-22250-en.html
1- Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran
2- Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran , amirah@aut.ac.ir
Abstract:   (2823 Views)
Wire Electrical Discharge Machining (WEDM) is known as an advanced manufacturing process, especially for producing delicate and intricate shapes and cutting difficult-to-cut materials. Machining error on is an important problem associated with this process. The current paper investigates experimentally the machining errors of three-stage WEDM on the small straight and arced paths. To reveal the reason behind these errors and to compensate them, residual materials of each cutting stage on the straight and arced corner paths were separately measured and analyzed. Machining errors of each WEDM stage in both paths were accurately considered and the causes of these errors in the straight and small arced paths were experimentally and theoretically determined and discussed. Experiments showed that the roughing stage has such a serious deteriorating influence the machining errors on the arced paths that it cannot be compensated in the following finishing stages. The spark angle domains of the roughing stage on the arced paths were calculated and the effects of these domains on the machining errors due to wire diversion from the programmed path were analyzed. In addition, this research proposes a novel guide in multi-stage WEDM by defining some machining concepts and developing equations for error calculation of WEDM finishing stages on these paths. The machining errors estimated by equations have consistency with the related experimental ones. of this study can be employed in the accurate WEDM cuttings.
Full-Text [PDF 617 kb]   (1811 Downloads)    
Article Type: Original Research | Subject: Machining
Received: 2018/06/19 | Accepted: 2018/12/29 | Published: 2019/06/1

References
1. Nikravan AR, Kolahan F. Statistical analysis and optimization of process parameters for cutting rate and surface roughness in wire cut machining of TI-6AL-4V alloy. Modares Mechanical Engineering. 2015;15(9):141-152. [Persian] [Link]
2. Parvizian J, Abyar H, Abdullah A, Ghadiri Zahrani E. Accuracy of small radius corners in multi stage WEDM: Roughing parameters and geometrical analysis. Modares Mechanical Engineering. 2013;13(7):87-101. [Persian] [Link]
3. Selvakumar G, Sarkar S, Mitra S. Experimental investigation on die corner accuracy for wire electrical discharge machining of Monel 400 alloy. Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture. 2012;226(10):1694-1704. [Link] [DOI:10.1177/0954405412456660]
4. Dekeyser W, Snoeys R, Jean-Pierre. Geometrical accuracy of Wire-EDM. International Symposium for Electromachining, 1 January, 1989, Nagoya, Japan. Unknown Publisher City?: Unknown Publisher; 1989. [Link]
5. Magara T, Yatomi T, Yamada H, Kobayashi K. Study on machining accuracy in Wire-EDM: Improvement of machining accuracy of corner parts in rough-cutting. Journal of the Japan Society of Electrical Machining Engineers. 1991;25(49):23-32. [Japanese] [Link] [DOI:10.2526/jseme.25.23]
6. Magara T, Yatomi T, Yamada H, Kobayashi K. Study on machining accuracy in Wire-EDM: Improvement of machining accuracy of corner parts in finish-cutting. Journal of the Japan Society of Electrical Machining Engineers. 1992;26(52):1-15. [Japanese] [Link] [DOI:10.2526/jseme.26.52_1]
7. Dauw DF, Beltrami I. High-precision Wire-EDM by online wire positioning control. CIRP Annals. 1994;43(1):193-197. [Link] [DOI:10.1016/S0007-8506(07)62194-5]
8. Hsue WJ, Liao YS, Lu SS. A study of corner control strategy of Wire-EDM based on quantitative MRR analysis. International Journal of Electrical Machining. 1999;4:33-39. [Link] [DOI:10.2526/ijem.4.33]
9. Obara H, Kawai T, Ohsumi T, Hatano M. Combined power and path control method to improve corner accuracy of rough cuts by Wire EDM (1st Report). International Journal of Electrical Machining. 2003;8:27-32. [Link] [DOI:10.2526/ijem.8.27]
10. Obara H, Ohsumi T, Imai W, Yamagishi Y, Hatano M. Combined power and path control method to improve corner accuracy of rough cuts by Wire EDM (2nd report). International Journal of Electrical Machining. 2003;8:33-38. [Link] [DOI:10.2526/ijem.8.33]
11. Puri AB, Bhattacharyya B. An analysis and optimisation of the geometrical inaccuracy due to wire lag phenomenon in WEDM. International Journal of Machine Tools and Manufacture. 2003;43(2):151-159. [Link] [DOI:10.1016/S0890-6955(02)00158-X]
12. Sanchez JA, López De Lacalle LN, Lamikiz A. A computer-aided system for the optimization of the accuracy of the wire electro-discharge machining process. International Journal of Computer Integrated Manufacturing. 2004;17(5):413-420. [Link] [DOI:10.1080/09511920310001626590]
13. Sanchez JA, Rodil JL, Herrero A, Lopez De Lacalle LN, Lamikiz A. On the influence of cutting speed limitation on the accuracy of Wire-EDM corner-cutting. Journal of Materials Processing Technology. 2007;182(1-3):574-579. [Link] [DOI:10.1016/j.jmatprotec.2006.09.030]
14. Han F, Zhang J, Soichiro I. Corner error simulation of rough cutting in Wire EDM. Precision Engineering. 2007;31(4):331-336. [Link] [DOI:10.1016/j.precisioneng.2007.01.005]
15. Han F, Cheng G, Feng Z, Isago S. Thermo-mechanical analysis and optimal tension control of micro wire electrode. International Journal of Machine Tools and Manufacture. 2008;48(7-8):922-931. [Link] [DOI:10.1016/j.ijmachtools.2007.10.024]
16. Dodun O, Gonçalves-Coelho AM, Slătineanu L, Nagit G. Using wire electrical discharge machining for improved corner cutting accuracy of thin parts. International Journal of Advanced Manufacturing Technology. 2009;41(9):858-864. [Link] [DOI:10.1007/s00170-008-1531-4]
17. Di Sh, Chu X, Wei D, Wang Z, Chi G, Liu Y. Analysis of kerf width in micro-WEDM. International Journal of Machine Tools and Manufacture. 2009;49(10):788-792. [Link] [DOI:10.1016/j.ijmachtools.2009.04.006]
18. Sarkar S, Sekh M, Mitra S, Bhattacharyya B. A novel method of determination of wire lag for enhanced profile accuracy in WEDM. Precision Engineering. 2011;35(2):339-347. [Link] [DOI:10.1016/j.precisioneng.2011.01.001]
19. Chen Z, Huang Y, Zhang Z, Li H, Yi Ming W, Zhang G. An analysis and optimization of the geometrical inaccuracy in WEDM rough corner cutting. The International Journal of Advanced Manufacturing Technology. 2014;74(5-8):917-929. [Link] [DOI:10.1007/s00170-014-6002-5]
20. Charmilles Company. User manual Robofil 200. Unknown Publisher City: Charmilles Technologies; 1989. [Link]
21. Abyar Firoozabadi H, Abdullah A, Parvizian J. Accurate machining of small-radius corners by Wire EDM. Journal of Mechanical Engineering. 2012;42(2):1-12. [Persian] [Link]
22. ASM International, Handbook Committee. ASM handbook: Heat treating. 10th Edition. 4th Volume. Russell Township: ASM International; 1991. [Link]

Add your comments about this article : Your username or Email:
CAPTCHA

Send email to the article author


Rights and permissions
Creative Commons License This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.