{"title":"Research and Development of Nontraditional Machining in China","authors":"Z. Wansheng, Zhu Di, Wang Zhenlong, Guo Dongming","doi":"10.2526/ijem.5.1","DOIUrl":"https://doi.org/10.2526/ijem.5.1","url":null,"abstract":"This paper introduces some of the latest advancements of research and development on non-traditional ma chining methods in China. The achievements include some new technologies that attract many research efforts in China, those are laminated ED-Milling, mini EDM device with new driving mechanism and new driving tech nique, open system EDM-CNC, EDM of integral turbine disk, numerical simulation of flow field in EDM gap, SLS technology, NC-ECM, electroforming and magnetic abrasive machining.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"68 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115057680","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"The New Linear Motor Drive Revolution","authors":"S. Sano","doi":"10.2526/ijem.10.49","DOIUrl":"https://doi.org/10.2526/ijem.10.49","url":null,"abstract":"Sodick has been using the linear motor drive since 1999 successfully to bring a new revolution in the EDM machining field. Initially, the Die-sinker EDM was equipped with a z-axis liner motor drive which made high speed jumping possible and resulted in high speed machining. After this initial breakthrough, all wire-cut and die-sinker EDMs produced by Sodick were installed with linear motor drives for all axes of movement. Five years have passed since the initial production of linear motor driven EDMs and many of these earlier machines still maintain high levels of accuracy. In the future, linear motor driven machines will become more and more a necessity to ensure the creation of precision molds with high repeatability.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"81 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121187151","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Two- Phase Simulation of Electrochemical Machining","authors":"G. Mayank, M. Kunieda","doi":"10.2526/IJEM.22.31","DOIUrl":"https://doi.org/10.2526/IJEM.22.31","url":null,"abstract":"The machining accuracy of Electrochemical Machining (ECM) is affected by the temperature and bubbles. The effect of bubbles in the simulation can be considered by first calculating the volume fraction of gas distribution (using bubbly flow approximation in this study) and then approximating the effective conductivity in the inter-electrode gap by using Bruggemann equation. Since, Bruggemann equation is independent of bubble diameter and distribution, its dependency on that was investigated in this study. Moreover, the effect of the bubbles generated on the machining accuracy of the axi-symmetric work piece with different flow rates was also investigated.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"76 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123225714","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shinya Hayakawa, M. Yuzawa, M. Kunieda, N. Nishiwaki
{"title":"Time Variation and Mechanism of Determining Power Distribution in Electrodes during EDM Process","authors":"Shinya Hayakawa, M. Yuzawa, M. Kunieda, N. Nishiwaki","doi":"10.2526/ijem.6.19","DOIUrl":"https://doi.org/10.2526/ijem.6.19","url":null,"abstract":"The aim of this study is to determine the mechanism of the power distribution in electrodes during the electrical discharge machining (EDM) process. The time variation of the power distribution is first measured by comparing the measured temperatures of the electrodes with the calculated results. It is found that, in the earlier stage of each pulse discharge, the measured power distribution in electrodes is at most two thirds of the total discharge power. As the discharge duration increases, however, the power distribution in electrodes approaches the total discharge power, which coincides with the solution of the magnetohydrodynamic equations for the EDM discharge plasma when the plasma is assumed to be in local thermodynamic equilibrium and in a steady state. It is concluded that, during the discharge duration normally used in the EDM process, the gap condition is not in equilibrium and a large fraction of the discharge power is consumed in transient phenomena such as evaporating, dissociating and ionizing of the dielectric fluid.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"19 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124169789","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Influence of Bead Geometry on Weld Distortion in Laser Micro-welding of Thin Stainless Steel Sheet with High-speed Scanning","authors":"Y. Okamoto, S. Matsuoka, Tadanori Otowa, A. Okada","doi":"10.2526/IJEM.20.9","DOIUrl":"https://doi.org/10.2526/IJEM.20.9","url":null,"abstract":"In this study, the thermal deformation of thin stainless steel sheet was investigated in bead-on-plate welding by using a single-mode fiber laser with Galvano scanning system. The numerical simulation was carried out to calculate temperature and stress fields, and its deformation characteristics were discussed. It was suggested that a specimen firstly deformed downward in the same direction of laser irradiation, and then deformed in the reversed direction after laser scanning. The final distortion angle in the negative direction, which is concave shape from the view direction of laser irradiation, was generated under the heat conduction and quasi-penetration welding mode, and the positive angle was obtained as the final distortion angle under the full-penetration welding mode. On the other hand, a small distortion could be achieved by the proper weld bead geometry in micro-welding of thin sheet, but the welding mode of minimum distortion conditions varied with specimen thickness. However, these relationships obtaining a small distortion could be understood by the relationship between aspect ratio of weld bead and distortion angle. Minimum angle of distortion could be achieved around maximum aspect ratio of weld bead regardless of specimen thickness and spot diameter, when an inflection point appeared in relationship between aspect ratio of weld bead geometry and distortion angle.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114626232","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Electropolishing of A Spherical Surface and the Application of Fuzzy Inference","authors":"H. Hocheng, S. Wei, C. Kuo","doi":"10.2526/ijem.4.19","DOIUrl":"https://doi.org/10.2526/ijem.4.19","url":null,"abstract":"Various dies and molds involving the spherical surface demand a good surface fmish, in which case either long period of time or expensive equipment for the polishing work is needed. An alternative to the conventionally used polishing method is investigated in the current study. The reported electropolishing can improve the maximum surface roughness to the extent of one order of magnitude within ten seconds of total on-time, and it requires an inexpensive equipment only. The whole-bright condition throughout the polished surface is achieved. The effects of the processing parameters of initial gap width, the electrolyte flow rate, the electrical voltage and the on/off period are studied. The axial stroke motion in phase with the on/off period is found advantageous. For such a nonlinear system of electropolishing, the authors present the use of the fuzzy inference to predict the obtained surface fmish and to design the polishing parameters, where the commonly used linear regression method is of limited use.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"24 26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128464400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
T. Shinonaga, Mitsuhiro Kimura, Motohiro Inoue, A. Okada
{"title":"Study on Improvement of Wear Resistance for Zirconia by Large-area Electron Beam Irradiation","authors":"T. Shinonaga, Mitsuhiro Kimura, Motohiro Inoue, A. Okada","doi":"10.2526/ijem.24.27","DOIUrl":"https://doi.org/10.2526/ijem.24.27","url":null,"abstract":"Zirconia has been widely applied for cutting tools and biomaterials, since it has superior mechanical properties such as high fracture toughness, bending strength and biocompatibility in ceramics. In order to maintain its surface functions for long-term, further improvement of wear resistance for zirconia has been required. In this study, improvement of wear resistance for zirconia is proposed by large-area electron beam (EB) irradiation. Experimental results show that mean width in roughness curve of zirconia surface increases with increasing the energy density of EB, although the maximum height in surface roughness is almost same as the ground surface. In friction and wear test, coefficient of friction reduces with increasing the energy deinsity of EB since ball material smoothly slides on the EB irradiated zirconia surface. Furthermore, it is made clear that wear resistance of zirconia significantly improves by the EB irradiation under appropriate energy density.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"51 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128857732","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Study on Laser Drilling Process of Solid Metal on Its Liquid","authors":"Y. Okamoto, Nozomi Taura, A. Okada","doi":"10.2526/ijem.27.35","DOIUrl":"https://doi.org/10.2526/ijem.27.35","url":null,"abstract":"","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128359791","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Examination of the Internal Profiles of Micro-Electrodischarge Machined Holes and the Detection of Material Defects","authors":"H. Almond, D. Allen, Peter Logan","doi":"10.2526/ijem.5.29","DOIUrl":"https://doi.org/10.2526/ijem.5.29","url":null,"abstract":"Micro-electrodischarge machining (micro-EDM) is used to machine micro-features such as holes, slots and cavities in electrically conductive materials. This paper looks at the fabrication of micro-holes for ink jet printing nozzles where hole diameters are smaller than SOJ.lm. It is important that the printing medium be able to flow through unimpeded, so the bore must be as smooth as possible. However, it is difficult to inspect the internal profiles of such small features non-destructively. In this study, micro-holes were machined along the join between two adjacent foils to provide a natural means of separation without using a secondary process to cut the holes in half. It was then possible to investigate the holes and unmachined control samples using scanning electron microscopy (SEM). It was found that defects such as micro-cavities, cracks and inclusions were already present prior to machining by micro-EDM, seemingly as a result of the material rolling process.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128301164","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"The Reduction of Tool Wear and Machining Time for the Micro-Electro-Discharge Machining of Micro-holes by Using Copper Vapour Laser Machining as a Roughing Process","authors":"M. David, X. Sue","doi":"10.2526/ijem.2.9","DOIUrl":"https://doi.org/10.2526/ijem.2.9","url":null,"abstract":"Micro-electro-discharge machining (micro-EDM) has displayed excellent machined surface quality, but in comparison with other non-traditional machining processes, slow machining speed and high tool wear rate were considered as the major disadvantages of this process. With the increasing demand for higher-precision machining, mass production and widening applications of micro-EDM, new technologies are urgently needed to meet the requirements of reducing machining time and electrode tool wear. This paper describes a novel combination of machining processes to fabricate small holes. Before the micro-EDM of the holes, copper vapour laser radiation is used to ablate an array of small holes first. These holes are then processed in a micro-EDM machine. The experimental results showed that the machining speed of micro-EDM has been improved and tool wear was also reduced while the surface quality remains the same.","PeriodicalId":407646,"journal":{"name":"International Journal of Electrical Machining","volume":"128 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128481766","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}