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TECHNICAL PAPERS

Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 1: Concept, Design, and Material Removal Rate

[+] Author and Article Information
Jun Qu, Albert J. Shih

Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695

Ronald O. Scattergood

Department of Materials Science and Engineering, North Carolina State University, Raleigh, NC 27695

J. Manuf. Sci. Eng 124(3), 702-707 (Jul 11, 2002) (6 pages) doi:10.1115/1.1475321 History: Received May 01, 2001; Revised December 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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References

Masuzawa,  T., Fujino,  M., Kobayashi,  K., and Suzuki,  T., 1985, “Study on Micro-Hole Drilling by EDM,” Bull. Jpn. Soc. Precis. Eng. , 20(2), pp. 117–120.
Masuzawa, T., Fujino, M., Kobayashi, K., Suzuki, T., and Fujii, H., 1986, “Wire Electro-Discharge Grinding System for Machining Very Fine Rods,” International Conference on Computer-Aided Production Engineering, Edinburgh, pp. 247–254.
Kuo, C.-L., Masuzawa, T., and Fujino, M., 1992, “High-Precision Micronozzle Fabrication,” IEEE Micro Electro Mechanical Systems ’92, Travemunde Germany, Feb. 4–7, pp. 116–121.
Masuzawa,  T., Kuo,  C.-L., and Fujino,  M., 1994, “A Combined Electrical Machining Process for Micronozzle Fabrication,” CIRP Ann., 43, pp. 189–192.
Langen,  H. H., Masuzawa,  T., and Fujino,  M., 1995, “Modular Method for Microparts Machining and Assembly with Self-Alignment,” CIRP Ann., 44, pp. 173–176.
Sun,  Xi-Qing, Masuzawa,  T., and Fujino,  M., 1996a, “Micro Ultrasonic Machining and its Applications in MEMS,” Sensors and Actuators, A57, pp. 159–164.
Sun, Xi-Qing, Masuzawa, T., and Fujino, M., 1996b, “Micro Ultrasonic Machining and Self-Aligned Multilayer Machining/Assembly Technologies for 3D Micromachines,” Proceedings of the IEEE Micro Electro Mechanical Systems (MEMS) 1996, Piscataway, NJ, pp. 312–317.
Masuzawa,  T., and Tonshoff,  H. K., 1997, “Three-Dimensional Micromachining by Machine Tools,” CIRP Ann., 46, pp. 621–628.
Yu,  Z. Y., Masuzawa,  T., and Fujino,  M., 1998, “Micro-EDM for Three-Dimensional Cavities-Development of Uniform Wear Method,” CIRP Ann., 47, pp. 169–172.
Rajurkar,  K. P., and Yu,  Z. Y., 2000, “3D Micro-EDM Using CAD/CAM,” CIRP Ann., 49, pp. 127–130.
Slocum, A. H., 1992, Precision Machine Design, Prentice Hall.

Figures

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The concept of cylindrical wire EDM process
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A cylindrical wire EDM part with the same shape as the diesel engine injector plunger
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Side view of the hybrid bearing underwater spindle
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Spindle error at 30 rpm rotational speed
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Spindle error vs. rotational speed
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FFT Frequency spectrum of the spindle error
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Parameters in the free form cylindrical wire EDM process
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Four test configurations to find the maximum material removal rate
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Key parameters of the two configurations to find the maximum material removal rate in cylindrical wire EDM
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Free form geometry in cylindrical wire EDM

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