An analysis of overcut variation and coupling effects of dimensional variable in EDM process

In the electrical discharge machining (EDM) process, the overcut greatly affects the precision and accuracy of the workpiece dimensions. However, the overcut and the final workpiece dimensions are difficult to predict due to the non-linear, complex relationship among the electrode wear, the electrode diameter, electrical discharging parameters, and the machine positioning accuracy. In the present study, the variation of the side overcut and the bottom overcut, the electrode dimensions, the spark hole dimensions, and the machine positioning accuracy in the EDM process are investigated. Variance analysis is used in a batch process under different electrical discharging parameters. The experiment results show that the coupling effect between the electrode diameter and spark hole diameter is an important factor for estimating the variation of the side overcut in the EDM process. With inclusion of the coupling effects, the predicted variation of side and bottom overcut in a batch EDM process and the EDM machine positioning accuracy is shown to be in good agreement with experimental results.

[1]  Biing-Hwa Yan,et al.  Micro-hole machining of carbide by electric discharge machining , 1999 .

[2]  Masanori Kunieda,et al.  Reverse Simulation of Die-Sinking EDM , 1999 .

[3]  Aitzol Lamikiz,et al.  Dimensional accuracy optimisation of multi-stage planetary EDM , 2002 .

[4]  V. N. Gaitonde,et al.  Investigations into the effect of tool shapes with size factor consideration in sink electrical discharge machining (EDM) process , 2009 .

[5]  Mark D. Semon,et al.  POSTUSE REVIEW: An Introduction to Error Analysis: The Study of Uncertainties in Physical Measurements , 1982 .

[6]  Bijoy Bhattacharyya,et al.  Comparative study of different dielectrics for micro-EDM performance during microhole machining of Ti-6Al-4V alloy , 2010 .

[7]  F. Amorim,et al.  The influence of generator actuation mode and process parameters on the performance of finish EDM of a tool steel , 2005 .

[8]  N. Mohri,et al.  Electrode Wear Process in Electrical Discharge Machinings , 1995 .

[9]  Vishal S. Sharma,et al.  Review of research work in sinking EDM and WEDM on metal matrix composite materials , 2010 .

[10]  Abdulkadir Erden,et al.  Geometry and surface damage in micro electrical discharge machining of micro-holes , 2009 .

[11]  Øyvind Bjørke,et al.  Computer Aided Tolerancing , 1989 .

[12]  Renjie Ji,et al.  Investigation of emulsion for die sinking EDM , 2010 .

[13]  Elman C Jameson,et al.  Electrical Discharge Machining , 2001 .

[14]  Bijoy Bhattacharyya,et al.  Investigation of electro-discharge micro-machining of titanium super alloy , 2009 .

[15]  S. H. Yeo,et al.  Analytical approximation of the erosion rate and electrode wear in micro electrical discharge machining , 2008 .

[16]  Y. Wong,et al.  A study on the quality micro-hole machining of tungsten carbide by micro-EDM process using transistor and RC-type pulse generator , 2009 .

[17]  Stephen T. Newman,et al.  State of the art electrical discharge machining (EDM) , 2003 .

[18]  Yogesh B. Gianchandani,et al.  Achieving precision in high density batch mode micro-electro-discharge machining , 2008 .

[19]  C. Wykes,et al.  A new method of optimising material removal rate using EDM with copper–tungsten electrodes , 2000 .

[20]  Chong Nam Chu,et al.  Micro electrical discharge milling using deionized water as a dielectric fluid , 2007 .

[21]  Mahmudur Rahman,et al.  Performance analysis of EDM electrode fabricated by localized electrochemical deposition for micro-machining of stainless steel , 2010 .

[22]  Mohan Kumar Pradhan,et al.  Neuro-fuzzy and neural network-based prediction of various responses in electrical discharge machining of AISI D2 steel , 2010 .

[23]  P.Narender Singh,et al.  Electric discharge machining of Al–10%SiCP as-cast metal matrix composites , 2004 .

[24]  Y. Liu,et al.  Effect of technological parameter on the process performance for electric discharge milling of insulating Al2O3 ceramic , 2008 .