Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

doi:10.1007/s11465-011-0246-7

Front Mech Eng

0, Vol.

Issue () : 419-428 https://doi.org/10.1007/s11465-011-0246-7

RESEARCH ARTICLE

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

Mohammadreza SHABGARD(

), Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

Department of mechanical Engineering, University of Tabriz, Tabriz, Iran

Download: PDF(525 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of ultrasonic vibration of workpiece on the characteristics of Electrical Discharge Machining (EDM) process of FW4 Welding Metal in comparison with the conventional EDM process. The studied process characteristics included the material removal rate (MRR), tool wear ratio (TWR), and surface roughness (R_a and R_max) of the workpiece after the EDM and ultrasonic assisted EDM (US-EDM) processes. The experiments performed under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The experimental results show that in short pulse on-times, material removal rate in the US-EDM process is approximately quadruple than that of the EDM process. On the contrary, in the long pulse on-times, ultrasonic vibration of work??piece leads to the reduction in the MRR. On the other hand, in short pulse on-times, the TWR in the US-EDM process is lower than that of in the EDM process, and this condition reverses with increase in the pulse on-time. Furthermore, the surface roughness of the workpiece machined by EDM process is slightly lower than that of applied to the US-EDM process.

Keywords electrical discharge machining (EDM) material removal rate (MRR) tool wear ratio (TWR) surface roughness

Corresponding Author(s): SHABGARD Mohammadreza,Email:mrshabgard@tabrizu.ac.ir

Issue Date: 05 December 2011

Cite this article:

Ramin Mohammadpour SHOTORBANI,Mohammadreza SHABGARD,Hamed KAKOLVAND, et al. Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal[J]. Front Mech Eng, 0, (): 419-428.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-011-0246-7
https://academic.hep.com.cn/fme/EN/Y0/V/I/419

Fig.1 Schematic diagram of production route of molds made of weld metal. (a) Mill-removing of the insert’s place; (b) MIG-welding of the insert place; (c) grinding of the mold face; (d) ED machining of the mold

Fig.2 Schematic construction of the experiment

Fig.3 Ultrasonic head assembled to the EDM head

Tab.1 Mechanical and physical properties of the work??piece and tool material

Tab.2 Experimental conditions

Fig.4 (a) Cylindrical rod cut with Wire-EDM; (b) final workpiece that has been Machined and screwed; (c) machined graphite tool machined

Fig.5 MRR vs. pulse on-time ( = 4 A)

Fig.6 MRR vs. pulse on-time ( = 8 A)

Fig.7 Effects of vibration on the plasma particles []

Fig.8 Typical records of the voltage and pulse current. (a) US-EDM process ( = 4 A and = 6.4 μs); (b) EDM process ( = 4 A and = 6.4 μs); (c) US-EDM process ( = 4 A and = 50 μs)

Fig.9 Typical pictures showing the presence of a black film on the surface of workpiece after the machining process. (a) EDM process ( = 4 A and = 6.4 μs); (b) US-EDM process ( = 4 A and = 6.4 μs); (c) EDM process ( = 4 A and = 50 μs); (d) US-EDM process ( = 4 A and = 50 μs)

Fig.10 TWR vs. pulse on-time ( = 4 A)

Fig.11 TWR vs. pulse on-time ( = 8 A)

Fig.12 TW vs. pulse on-time ( = 4 A)

Fig.13 TW vs. pulse on-time ( = 8 A)

Fig.14 Microscopic photograph of graphite surface before exposing to the ultrasonic vibration (without spark)

Fig.15 Microscopic photograph of graphite surface after exposing to the ultrasonic vibration (without spark)

Fig.16 vs. pulse on-time (= 4 A)

Fig.17 vs. pulse on-time ( = 8 A)

Fig.18 vs. pulse on-time ( = 4 A)

Fig.19 vs. pulse on-time (= 8 A)

1	Ho K H, Newman S T. State of the art electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture , 2003, 43(13): 1287–1300 doi: 10.1016/S0890-6955(03)00162-7
2	Norliana Mohd A, Solomon D G, Fuad Bahari, Md. A review on current research trends in electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture , 2007, 47(7–8): 1214–1228 doi: 10.1016/j.ijmachtools.2006.08.026
3	I. T. FORGING Co., http://www.itforging.com/
4	Corewire Welding Technology, http://www.corewire.com/
5	Shabgard M R, Shotorbani R M. Mathematical modeling of machining parameters in electrical discharge machining of FW4 welded steel. World Academy of Science, Engineering and Technology , 2009, 52: 403–409
6	Shabgard M R, Sadizadeh B, Kakoulvand H. The effect of ultrasonic vibration of workpiece in electrical discharge machining of AISIH13 tool steel. World Academy of Science, Engineering and Technology , 2009, 52: 392–396
7	Kremer D, Lhiaubet C, Moisan A. A study of the effect of synchronizing ultrasonic vibrations with pulses in EDM. CIRP Annals-Manufacturing Technology , 1991, 40(1): 211–214 doi: 10.1016/S0007-8506(07)61970-2
8	Thoe T B, Aspinwall D K, Killey N. Combined ultrasonic and electrical discharge machining of ceramic coated nickel steel. Journal of Materials Processing Technology , 1999, 92–93(1): 323–328 doi: 10.1016/S0924-0136(99)00117-X
9	Lin Y C, Yan B H, Chang Y S. Machining characteristic of titanium alloy (Ti-6AI-4V) using a combination process of EDM with USM. Journal of Materials Processing Technology , 2000, 104(3): 171–177 doi: 10.1016/S0924-0136(00)00539-2
10	Lin Y C, Yan B H, Huang F Y. Surface modification of AI-Zn-Mg aluminum alloy using the combined process of EDM with USM. Journal of Materials Processing Technology , 2001, 115(3): 359–366 doi: 10.1016/S0924-0136(01)01017-2
11	Ghoreishi M, Atkinson J. A comparative experimental study of machining characteristics in vibratory, rotary and vibro-rotary electro discharge machining. Journal of Materials Processing Technology , 2002, 120(1–3): 374–384 doi: 10.1016/S0924-0136(01)01160-8
12	Zhao W S, Wang Z L, Di S C, Chi G X, Wei H Y. Ultrasonic and electric discharge machining to deep and small hole on titanium alloy. Journal of Materials Processing Technology , 2002, 120(1–3): 101–106 doi: 10.1016/S0924-0136(01)01149-9
13	Gao C S, Liu Z X. A study of ultrasonically aided micro-electrical-discharge machining by the application of workpiece vibration. Journal of Materials Processing Technology , 2003, 139(1–3): 226–228 doi: 10.1016/S0924-0136(03)00224-3
14	Egashira K, Matsugasako A, Tsuchiya H, Miyazaki M. Electrical discharge machining with ultra low discharge energy. Precision Engineering , 2006, 30(4): 414–420 doi: 10.1016/j.precisioneng.2006.01.004
15	Chern G L, Wu Y J E, Liu S F. Development of a micro-punching machine and study on the influence of vibration machining in micro-EDM. Journal of Materials Processing Technology , 2006, 180(1–3): 102–109 doi: 10.1016/j.jmatprotec.2006.05.010
16	Shabgard M R, Ivanov A, Rees A. Influence of EDM machining on surface integrity of WC-Co. Manufacturing Engineering Centre, Cardiff University , 2006
17	Shervani-Tabar M T, Abdullah A, Shabgard M R. Numerical study on the dynamics of an electrical discharge generated bubble in EDM. Engineering Analysis with Boundary Elements , 2006, 30(6): 503–514 doi: 10.1016/j.enganabound.2006.01.014
18	Jones H M, Kunhardt E E. The Influence of pressure and conductivity on the pulsed breakdown of water. IEEE Transactions on Dielectrics and Electrical Insulation , 1994, 1(6): 1016–1025 doi: 10.1109/94.368641
19	Takeshi H, Minoru H, Toshiaki O. A Mechanical vibration assisted plasma etcher for etch rate improvement. Journal of the International Societies for Precision Engineering and Nanotechnology , 2002, 26: 137–141
20	Roth J R. Industrial Plasma Engineering Volume 2: Applications to Non-thermal Plasma Processing. Bristol: IOP Publishing Ltd. , 2001
21	Elman C. Jameson, Electrical Discharge Machining. Society of Manufacturing Engineers , 2001

[1]	Xiaojun TAN, Haibing XIAO, Zihong WANG, Wei ZHANG, Zhijuan SUN, Xuyun PENG, Zhongmin LIU, Liang GUO, Qingmao ZHANG. Laser polishing of a high-entropy alloy manufactured by selective laser melting[J]. Front. Mech. Eng., 2024, 19(5): 34-.
[2]	Min YANG, Hao MA, Zhonghao LI, Jiachao HAO, Mingzheng LIU, Xin CUI, Yanbin ZHANG, Zongming ZHOU, Yunze LONG, Changhe LI. Force model in electrostatic atomization minimum quantity lubrication milling GH4169 and performance evaluation[J]. Front. Mech. Eng., 2024, 19(4): 28-.
[3]	Peng LYU, Min LAI, Yifei SONG, Zhifu XUE, Fengzhou FANG. Sub-nanometer finishing of polycrystalline tin by inductively coupled plasma-assisted cutting[J]. Front. Mech. Eng., 2023, 18(3): 35-.
[4]	Jiqiang WU, Liqin WANG, Zhen LI, Peng LIU, Chuanwei ZHANG. Thermal analysis of lubricated three-dimensional contact bodies considering interface roughness[J]. Front. Mech. Eng., 2022, 17(2): 16-.
[5]	Gang SHEN, Jufan ZHANG, David CULLITON, Ruslan MELENTIEV, Fengzhou FANG. Tribological study on the surface modification of metal-on-polymer bioimplants[J]. Front. Mech. Eng., 2022, 17(2): 26-.
[6]	Zequan YAO, Chang FAN, Zhao ZHANG, Dinghua ZHANG, Ming LUO. Position-varying surface roughness prediction method considering compensated acceleration in milling of thin-walled workpiece[J]. Front. Mech. Eng., 2021, 16(4): 855-867.
[7]	Zhigang DONG, Qian ZHANG, Haijun LIU, Renke KANG, Shang GAO. Effects of taping on grinding quality of silicon wafers in backgrinding[J]. Front. Mech. Eng., 2021, 16(3): 559-569.
[8]	Arun KRISHNAN, Fengzhou FANG. Review on mechanism and process of surface polishing using lasers[J]. Front. Mech. Eng., 2019, 14(3): 299-319.
[9]	Rupesh CHALISGAONKAR, Jatinder KUMAR. Optimization of WEDM process of pure titanium with multiple performance characteristics using Taguchi’s DOE approach and utility concept[J]. Front Mech Eng, 2013, 8(2): 201-214.
[10]	CHEN Hao-sheng, CHEN Da-rong, WANG Jia-dao, LI Yong-jian. Calculated journal bearing lubrication of non-Newtonian medium with surface roughness effects[J]. Front. Mech. Eng., 2006, 1(3): 270-275.

Viewed

Full text

Abstract

Cited

Shared

Discussed