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Abrasion Assisted Wire EDM
- 1. Assessment of Abrasion-Assisted MaterialRemoval in Wire EDM I. Menzies, P. Koshy McMaster University, Canada 58th CIRP General Assembly, Manchester August 25, 2008
- 2. 1970 generator technology coated wires highpressure flushing adaptive control workpiece height & taper surface finish machining accuracy & precision 2/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 3. Aspinwall et al(2008) rough trim Machining speed & surface integrity continue to be issues of focus in current wire EDM research surface integrity Kruth et al (2004) ~40X cutting rate 3/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 4. The issues of machiningspeed and surface integrity are interlinked Aspinwall et al (2003) 4/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 5. Enhancing the ejectionefficiency is the key to simultaneously improving the removal rate and the surface integrity Need for innovation 5/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 6. Hybrid machining entailsthe integration of processes with distinct mechanisms of material removal to exploit their synergy El-Hofy (2005) 6/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 7. Grinding + EDM Thermalsoftening of workpiece In-process dressing & declogging 7/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 8. Extension of theconcept to wire EDM wire rod Masuzawa et al (1985) discharge area Different from Wire Electro Discharge Grinding 8/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 9. wire Material removal by melting/vaporizationand two-body abrasion ph > gw reference voltage dielectric strength 9/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 10. Fixed abrasive diamond wireused in the electronics industry Issues with wire guide and electrical power feed 10/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 11. average voltage 108 –162V peak current 1.2 – 8 A open voltage 180 V on time 4.9 μs off time 100 μs wire tension 6.8 N wire speed 5.5 m/min SAE 1018 steel & Nickel 600 dielectric oil; 1 bar flushing pressure machining gap 8 – 20 µm removal rate 0.02 – 0.10 mm2/min wire failure by embrittlement experiments using wire with no abrasives for comparison of removal rate & recast layer, and estimation of gap-width 11/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 12. Wire characterization 180 microncore 50 micron (nominal) diamond 12/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 13. Force measurement byconsidering force equilibrium in reference to wire bow and wire tension 13/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 14. wire sawing edm Order of magnitude enhancementin the removal rate Steepest gradient in the increase in removal rate is in line with the maximum force gradient 14/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 15. 108 V, 8A Increase in the removal rate is due to abrasion 20 m 162 V, 8 A 15/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 16. wire-EDM Machined surface 108 V,8 A abrasion-assisted Wire performance degrades rapidly with repeated use used wire 16/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 17. Comparison of recastmaterial nickel steel wire-EDM abrasion-assisted 17/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 18. Wire feed strategies 18/20 Assessmentof abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008
- 19. Conclusions & Outlook Proof-of-conceptof an innovative abrasionassisted wire EDM process has been presented The process has the potential to significantly enhance the removal rate and the quality of the machined surface, particularly for metal matrix composites that are difficult to wire EDM The process is perhaps best implemented on a twin-wire machine tool Research effort is required to formulate wires with aluminum oxide abrasives, with a core that has good sparking and grain retention characteristics Electrical discharges could possibly enhance wire sawing of brittle materials through controlled thermal shock-induced fracture Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 19/20 58th CIRP General Assembly Manchester, August 25, 2008
- 20. Thank you for your attention! NaturalSciences & Engineering Research Council of Canada 20/20 Assessment of abrasion-assisted material removal in wire EDM I. Menzies, P. Koshy 58th CIRP General Assembly Manchester, August 25, 2008