Spark Analysis Based on the CNN-GRU Model for WEDM Process (original) (raw)
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Wire electrical discharge machining (WEDM) is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). WEDM demands high cutting rate and high quality to improve machining performance for manufacturing hard materials. The machining performance of computer-controlled WEDM is directly dependent on spark energy and pulse frequency parameters including discharge voltage, peak current, pulse duration, and charging time. In this paper, a new performance index to measure the effects of spark energy and pulse frequency on machining performance is proposed. Moreover, the effects of electric process parameters on performance measures including cutting speed, surface roughness, and white layer thickness are introduced.
Review on Current Research Trends in Wire Electrical Discharge Machining (WEDM)
Indian Journal of Science and Technology
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters , include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Furthermore, different types of WEDM methods introduced and discussed. In addition the paper highlights different modelling and optimization methods and discussed their advantage and disadvantage. The final part of the paper includes some recommendations about the trends for future WEDM researches.
International Journal of Machine Tools and Manufacture, 2004
The development of new, advanced engineering materials and the need for precise and flexible prototypes and low-volume production have made the wire electrical discharge machining (EDM) an important manufacturing process to meet such demands. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits are identified. An envelope of feasible EDM process parameters is generated for each work-material. Applications of such a process envelope to select process parameters for maximum MRR and for machining of micro features are discussed. Results of Scanning Electron Microscopy (SEM) analysis of surface integrity are presented.
Electrical Discharge Machining: An Overview on Various Areas of Research
Manufacturing and Industrial Engineering, 2014
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. A spark occurs in a small gap between the work piece and the electrode and removes the material from the work piece through melting and vaporising. The electrode and the work piece must be electrically conductive in order to generate the spark. Various types of products can be produced and/or finished using EDM such as dies, moulds, parts of aerospace, automotive industry and surgical components etc. This paper presents the various research issues in EDM along with the modelling technique in predicting EDM performances.
Study on Electrical Discharge Machining and Effect of its Parameters
The Electrical Discharge Machining (EDM) is one of the most common and most accepted non-traditional machining processes used in tooling industries. EDM is an important manufacturing method developed in 1940's. The forming tools to produce plastic molding die casting, forging dies etc. It is an electro-thermal process and is based on eroding effect of an electrical spark on both electrode and work piece. It is a thermal erosion process where metal removal takes place by series of recurring electrical discharges between cutting tool acting as an electrode and a conductive work piece in the presence of a dielectric fluid. The dielectric fluid will be flooded in a small gap of about 0.01mm to 0.5mm. This discharge occurs in voltage gap between the electrode and work piece. Currently, non-traditional process possess virtually unlimited capabilities except for volumetric material removal rates, for which great advances here been made in past few years to increase the cost effectivene...
International Journal of Advanced Technology and Engineering Exploration, 2016
Wire electrical discharge machining (WEDM) is a unconventional process of machining. It is utilised in conditions where workpiece is very hard to cut by conventional machining processes. This process machines electrically conductive materials [1]. The machining is carried out by controlled electrical sparks in a dielectric medium [2]. No stresses are developed in this process because there is no physical contact between the tool and the workpiece. When potential difference is applied between the tool and the workpiece the dielectric breaks down allowing the flow of spark, which causes erosion on workpiece and on tool also. The magnitude of erosion is more on the workpiece than on the tool (i.e. constantly travelling wire). Wire electrical discharge machining is a complex process owing to the number of variable that control the process.
Current Research Trends in Wire Electrical Discharge Machining (WEDM): A Review
2018
Wire Electrical Discharge Machine (WEDM), a non-traditional machining process, is becoming more important in providing a non-contact machining process. It is suitable for machining geometrically complex and hard advanced material which is impossible to machine using the conventional machine. This paper reviewed the experimental results on performance evaluation of machining parameters which affected machining performance which would reflect the machining factors and responses. In addition, the methods in analyzing, modelling, development and tool steel in WEDM were also discussed. Some recommendations and future WEDM research were proposed.
2009
Electrical Discharge Machining (EDM) is a non-conventional machining process whose thermoelectric nature makes it suitable for the machining of any material, regardless of its hardness and of its brittleness, as long as it conducts electricity. Despite EDM is a popular process in industry, the fact that it involves phenomena of very distinct natures (electrical, thermal, chemical and metallurgical) together with the difficulty inherent to the experimental study of the discharge process, there is a lack of scientific knowledge about it. The present work aims to help in this sense, providing a novel modeling tool capable of simulating discharge superposition, which allows the prediction of surface topographies and temperature fields due to discharges. Based on the comparison between results of simulations (material removal rates and surface topographies) and experimental measurements the discharge process can be characterized using an inverse method. Here, the basis of the developed model will be presented, together with the methodology employed to find out the parameters which define discharge properties. Results obtained with this inverse method have been included.
ARTICLE INFO ABSTRACT Generally the non-convectional machining processes use thermal source of energy for the material removal. Among them Electrical discharge machining (EDM) or spark erosion machining is most important one. The important process parameters in this technique are discharge pulse on time, discharge pulse off time current and gap voltage. The values of these parameters significantly affect such machining outputs as material removal rate. In the present research, an axisymmetric thermo-physical finite element model for the simulation of single sparks machining during electrical discharge machining (EDM) process is exhibited and the model has been solved by using ANSYS 11.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties has been used to investigate the temperature distribution on the surface. Material removal rate was calculated for multi-discharge machining by taking into considerations...