DOI QR코드

DOI QR Code

방전 드릴링에서 전극 소모량 예측 및 보정

A Study of Electrode Wear Estimation and Compensation for EDM Drill

  • 투고 : 2012.04.18
  • 심사 : 2013.01.06
  • 발행 : 2013.06.15

초록

Electric discharging machining (EDM) is commonly adopted to machine the precise and tiny part when it is difficult to meet the productivity and the tolerance by the conventional cutting method. The die-sinking EDM method works well to machine the micro-parts and the perpendicular wall of die and mould, whereas EDM drilling, called super drill, is excellent to machine the deep and narrow hole regardless the material hardness and the hole location. However, the electrode wear is rapid compared to the conventional cutting tool and makes it difficult to control the electrode feeding and to machine precisely. This paper presents an efficient method to estimate the electrode wear using hole pass-through experiment while the stochastic method is used to compensate for the estimation model. To validate the proposed method, the commercial EDM drill machine is used. The experiment result shows that the electrode wear amount can be predicted very precisely.

키워드

참고문헌

  1. Bleys, P., Kruth, J. P., Lauwers, B., Zryd, A., Delpretti, R., and Tricarico, C. (2002), Real-time Tool Wear Compensation in Milling EDM, CIRP Annals Manufacturing Technology, 51(1), 157-160. https://doi.org/10.1016/S0007-8506(07)61489-9
  2. Chang, Y.-F. and Chiu, Z.-H. (2004), Electrode wear-compensation of electric discharge scanning process using a robust gap-control, Mechatronics, 14, 1121-1139. https://doi.org/10.1016/j.mechatronics.2004.06.005
  3. Jia, Z. X., Zhang, J. H. and Ai, X. (1997), Study on a new kind of combined machining technology of ultrasonic machining and electrical discharge machining, International Journal of Machine Tools and Manufacture, 37(2), 193-197. https://doi.org/10.1016/S0890-6955(96)00048-X
  4. Kalpajian, S. and Schmid, S. R. (2003), Material removal processes : abrasive, chemical, electrical and high-energy beam, in : Manufacturing Processes for Engineering Materials, Prentice Hall, New Jersey.
  5. Kim, B. H. (1999), Micro Hole Machining Using MEDM with Screw-Type Electrode, Master Thesis, Seoul University.
  6. Kim, Y. T., Park, S. J., and Lee, S. J. (2005), Micro/Meso-Scale Shapes Machining by Micro EDM Process, International Journal of Precision Engineering and Manufacturing, 6(2), 5-11.
  7. Kremer, D., Lebrun, J. L., Hosari, B., and Moisan, A. (1989), Effects of ultrasonic vibrations on the performances in EDM, CIRP Annals-Manufacturing Technology, 38(1), 199-202. https://doi.org/10.1016/S0007-8506(07)62684-5
  8. Kremer, D., Lhiaubet, C. and Moisan, A. (1991), A study of the effect of synchronizing ultrasonic vibrations with pulses in EDM, CIRP Annals-Manufacturing Technology, 40(1), 211-214. https://doi.org/10.1016/S0007-8506(07)61970-2
  9. Lee, C. S., Choi, I. H., Heo, E. Y., and Kim, J. M. (2012), A Method of Hole Pass-Through Evaluation for EDM Drilling, Journal of the Korean Institute of Industrial Engineers, 38(3), 220-226. https://doi.org/10.7232/JKIIE.2012.38.3.220
  10. Lee, C.-S., Heo, E.-Y., Hong, M.-S., and Kim, J.-M. (2011), A Study on the Optimal Machining Condition of the Micro Hole In Micro-EDM Process, The 21st International conference on Flexible Automation and Intelligent Manufacturing, TAIWAN, 409-414.
  11. Lee, C.-S., Kim, J.-M., Heo, E.-Y., Kim, B.-M., and Kim, D.-W. (2011), A Study on the Machinability of Micro Channel using Mircro-EDM, The 21st International conference on Flexible Automation and Intelligent Manufacturing, TAIWAN, 401-408.
  12. Lim, H. S., Wong, Y. S., Rahman, M., and Lee, M. K. F. (2003), A Study on the machining of high-aspect ration micro structures using micro-EDM, Journal of Materials Processing Technology, 140(1-3), 318-325. https://doi.org/10.1016/S0924-0136(03)00760-X
  13. Lin, J. L., Wang, K. S., Yan, B. H., and Tarng, Y. S. (2000), Optimization of the electrical discharge machining process based on the Taguchi method with fuzzy logics, Journal of Materials Processing Technology, 102, 48-55. https://doi.org/10.1016/S0924-0136(00)00438-6
  14. Lonardo, P. M. and Bruzzone, A. A. (1999), Effect of flushing and electrode material on die sinking EDM, CIRP Annals-Manufacturing Technology, 48(1), 123-126. https://doi.org/10.1016/S0007-8506(07)63146-1
  15. Marafona, J. and Wykes, C. (2000), A new method of optimising material removal rate using EDM with copper-tungsten electrodes, International Journal of Machine Tools and Manufacture, 40(2), 153-164. https://doi.org/10.1016/S0890-6955(99)00062-0
  16. Masuzawa, T., Fujino, M. and Kobayashi, K. (1985), Wire electro-discharge grinding for micro-machining, CIRP Annals-Manufacturing Technology, 34(1), 431-434. https://doi.org/10.1016/S0007-8506(07)61805-8
  17. Masuzawa, T., Ku, C. L. and Fujino, M. (1990), Drilling of Deep Microholes by EDMUsing Additional Capacity, Int. J. of the Japan Society of Precision Engineering, 23(4), 275-276.
  18. Masuzawa, T., Kuo C. L., and Fujino, M. (1994), A combined electrical machining process for micro nozzle fabrication, CIRP Annals-Manufacturing Technology, 43(1), 189-192. https://doi.org/10.1016/S0007-8506(07)62193-3
  19. Mohri, N., Suzuki, M., Furuya, M. and Saito, N. (1995), Electrode wear process in electrical discharge machining, CIRP Annals-Manufacturing Technology, 44(1), 165-168. https://doi.org/10.1016/S0007-8506(07)62298-7
  20. Mohri, N., Takezawa, H., Furutani, K., Ito, Y., and Sata, T. (2000), A new process of additive and removal machining by EDM with a thin electrode, CIRP Annals-Manufacturing Technology, 49(1), 123-126. https://doi.org/10.1016/S0007-8506(07)62910-2
  21. Yu, Z. Y., Masuzawa, T. and Fujino, M. (1998), Micro-EDM for three dimensional cavities development of uniform wear method, CIRP Annals-Manufacturing Technology, 47(1), 169-172. https://doi.org/10.1016/S0007-8506(07)62810-8