Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 1: Concept, Design, and Material Removal Rate
Author:
Qu Jun1, Shih Albert J.1, Scattergood Ronald O.2
Affiliation:
1. Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695 2. Department of Materials Science and Engineering, North Carolina State University, Raleigh, NC 27695
Abstract
Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of a precise, flexible, and corrosion-resistant underwater rotary spindle is first introduced. A detailed spindle error analysis identifies the major sources of error at different frequency spectrum. The spindle has been added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometries. The mathematical model for material removal rate of the free-form cylindrical wire EDM process is derived. Experiments were conducted to explore the maximum material removal rate for cylindrical and 2D wire EDM of carbide and brass work-materials. Compared to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates may be achieved in the cylindrical wire EDM, possibly due to better debris flushing condition.
Publisher
ASME International
Subject
Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering
Reference11 articles.
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