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Research Papers

Prediction Algorithm for WEDM Arced Path Errors Based on Spark Variable Gap and Nonuniform Spark Distribution Models

[+] Author and Article Information
Hamid Abyar

Department of Mechanical Engineering,
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran

Amir Abdullah

Department of Mechanical Engineering,
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
e-mail: amirah@aut.ac.ir

Abdolhamid Akbarzadeh

Department of Bioresource Engineering,
McGill University,
Island of Montreal, QC H9X 3V9, Canada;
Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada

1Corresponding author.

Manuscript received May 17, 2018; final manuscript received October 6, 2018; published online November 26, 2018. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 141(1), 011011 (Nov 26, 2018) (11 pages) Paper No: MANU-18-1325; doi: 10.1115/1.4041779 History: Received May 17, 2018; Revised October 06, 2018

Wire electrical discharge machining (WEDM) is a demanding high-precision process for machining of hard-to-machine materials. The main issue is manufacturing errors in shape and radius of small arcs generation. In this paper, a novel model about spark variable gap sizes and nonuniform spark distribution around the wire on arced path machining is first theoretically developed using spark angle domain and WEDM dynamic analysis. Applying spark-force distributed around the wire and resulting wire deflection are estimated by the WEDM conditions influenced by plasma channel specifications, discharge frequency, wire guide clearance, wire tension, and arc radius. Total theoretical arced machining errors including wire deflection and spark gap size variation around the wire interface are calculated based on the proposed model. In addition, machining errors of straight and small arced paths are experimentally analyzed under variation of WEDM influential parameters including discharge frequency, arced path radius (150, 300 and 450 μm), and wire tension through the statistical full factorial. Comparison of the results for different sets of variable parameters shows that the theoretical values of the arced machining errors can be consistent with the experimental one by a coefficient which depends on the machining conditions and the WED machine type. Finally, based on the theoretical and experimental results, a theoretical algorithm and an operational method with mean accuracy of 84.8% are proposed for predicting and compensating the errors of WEDM on the arced paths. Findings of this research can be used in high-accurate WEDM applications and industries.

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Figures

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Fig. 1

The WEDM process: (a) on the straight path (b) on the arced path

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Fig. 2

Arced path machining concepts; the spark envelope, variable gap, and resultant and its component forces

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Fig. 3

Wire deflection and its variations in case of the wire guides: (a) without clearance and (b) with clearance

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Fig. 4

Shape and sizes of the specimens and the measurement method

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Fig. 5

Crater diameters in scanning electron microscopy images of the machined surfaces

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Fig. 6

Comparison of the theoretical and experimental machining errors on the arced path at point B

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Fig. 7

The developed algorithm and error calculation method proposed in this paper

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