• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.5
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• pp.24-29
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• 2004

This paper presents the tension control of a wire-cut discharge machine using electrorheological(E,R) fluid based brake system. On the basis of the tension level required in the machine, an appropriate size of the ER brake which features design simplicity, fast response and salient controllability is designed. Considering the Bingham property of ER fluid and actuator response time, the governing equation of the ER brake is derived. And a tension propagation of wire electrode is modeled via frequency response. The tension control performance of the discharge machine is simulated by using a robust sliding mode controller.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.5
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• pp.101-106
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• 2008

In the wire cut electrical discharge machining, the optimal machining parameters setting satisfying the requirements of both high efficiency and good quality is very difficult because its process involves a series of complex physical phenomena and the machining parameters are numerous over diverse range. In this paper, the experimental investigation has been performed to find out the influence of the machining parameters on the machining performance such as cutting speed and surface roughness. The selected experimental parameters are no load voltage, discharge peak current and pulse-off time. The experimental results give the guideline for selecting suitable machining parameters.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.11
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• pp.171-178
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• 2004

This paper presents vibration characteristics of a wire cut discharge machine in which an electro-rheological brake actuator is used to control the wire tension. The ER brake actuator has several advantages including design simplicity, fast response time and real-time controllability. On the basis of the tension level required in the machine an appropriate size of the ER brake actuator is devised. The ER brake actuator is then incorporated with the machine and the field-dependent wire tension is experimentally evaluated. The straightness of the workpiece is also empirically investigated by changing the intensity of the electric field.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.6
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• pp.714-719
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• 2011

The surface roughness depending on the machining method is very important because is produce a finished product through riveting, sealing, bonding, and special paint in order to curb the turbulence and air resistance which occur between the sheets. Aluminum alloy 2024 which is widely used for interior and exterior material of aircraft are tested. Jin-young JW-60C wire cutting machine was used in this experiment. In this paper, the experimental investigation has been performed to find out the influence of the surface roughness and surface shape characteristics on the wire-cut EDM of discharge energy in aluminium alloy 2024. The selected experimental parameters are peak current, no-load voltage, off time and feed rate. The experimental results give the guideline for selecting reasonable machining parameters. The high discharge energy on the idle time, almost no change in surface roughness can be seen.

• Journal of the Korean Society of Safety
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• v.19 no.2
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• pp.21-25
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• 2004

This study deals with the characteristics of wire-cut EDM(Electrical Discharge Machining)process in aluminum alloys. Besides 2 series and 7 series of aluminum alloys for aerospace applications, porous aluminum is tested, which is used for sound absorbing matherial and interior and exterior material of building. Jinyoung JW-30 wire cutting machine was used in this experiment. Tap wate passed a filter and ionization was used as the discharging solution. An immerision method was applied as a cooling method because it separates chips effectively and machinability is good even with low value of electric current. The speed of fabrication was estimated by measuring the travel distance of the work piece and time spent for the movement. As pulse-on-time increased the fabrication speed decreased. On the other hand, as peak voltage of peak current increased the fabrication speed increased. In general 7075 aluminum alloy resulted in higher fabrication speed.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.172-178
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• 2001

Titanium alloys have lightness, high strength and good corrosion resistant characteristics, and broadly used in manufacturing parts for military and aerospace industries. And these alloys also are recognized for organism materials comparatively and used as fixing ones in the human body. Nevertheless thess alloys have excellent properties such as corrosion resistance, heat resistance, and good tensile strength, it is difficult to machine by traditional methods because of high hardness and chemically activated property. So higher tool wear is expected when cutting by tools. Therefore, it is required nontraditional machining process. And the mechanical characteristics such as surface structure and shape, hardness and bending strength are studied for wire electrical discharge machined and surface ground titanium alloys for various heat-treated conditions.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.9
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• pp.61-67
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• 2017

Research into the selection of suitable materials and the development of fast processing methods for press die manufacturing is absolutely necessary to reduce the production time and cost. In particular, knowledge of its heat properties must be considered whendeveloping a long press die. Generally, as the main component materials of press dies, Cr, W low alloy tool steel, high carbon-high chrome steel, high speed steel, etc., are used as thetooling steel for the cold die. Machine tools and wire-cut electric discharge machining are mainly used for processing the press die parts. There are many differences in the machining time and life cycle of die parts depending on the machining process. The parts produced by milling and grinding have a high manufacturing time and cost with a long life cycle, while thosemade by milling and wire-cut discharge machining have areduced manufacturing time and cost,whereastheir die life cycle is reduced. Therefore, in this study, we will discuss amethod of improving the life cycle of the die parts by using heat treatment as a processing method that reduces the manufacturing time and cost. SEM, EDS analysis and the surface roughness analysis of the surface and center of the workpiece are used for analyzing the specimens produced by three machining methods, viz. milling - grinding, milling - wire cut discharge, and milling - wire cut discharge - heat treatment. A method of making die parts having the same life cycle as those produced by milling - grinding is developed with the milling - wire cut discharge - high temperature tempering method.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.537-542
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• 2000

Wire deflection, surface roughness and roundness were observed on changing discharge time for electrical discharge machining(EDM) of STD-11 in various conditions of thickness. The wire deflection was decreased as increasing discharge time and wire tension. The deflection is the smallest at the speed of wire of 10.6m/min and the water specific resistivity of 5k$\Omega$.cm. The deflection is found to be decreased as increasing dwell time. But if the water pressure is high, it is found not to be changed after the vibration of 4sec. The component of copper(Cu) and zinc(Zn), which is the main material of wire electrode, is observed for rough wire-cutting EDM of STD-11. This phenomena is found to be similar in spite of the change of EDM energy level. But it will be improved by changing the material and the shape of wire. The roundness of middle is found to be worse than that of upper and it is increased as the thickness of material is increased.

• Journal of the Korean Society for Precision Engineering
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• v.5 no.4
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• pp.59-65
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• 1988

This paper describes the transmutation layer of CNC Wire electrical discharte machined surface. In order to analayze and invesigate transmutation layer of the carbon tool steel, workpieces was heat-treated by quenching, tempering, normaling. The obtained results are summarized as follows. 1. The result showed that wire electrical discharge machined surface region was transmuted into the recdast layer in the range of about 10${\mu}$m deep by resolidification and next zone was transmuted into the heat affected zone in the range of about 15${\mu}$m deep by high temperature. 2. The hardness of the recast layer and heat affected zone was decreased on its machined surface. 3. The more wire feedrate was increased, the more electrical discharge machine gap was decreased.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.567-572
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• 2000

From the experimental study of W-EDM for alloyed steel, the characteristics such as Hand Drum Form and surface roughness have been observed and evaluated for various conditions. In square hole, the increase of IP as to made condition, the calculate high value of surface roughness. Also compare dimensionless square hole with circle hole' graph, In circle hole, if a value of surface roughness IP 6 in a side of circle it show a 0.4${\mu}{\textrm}{m}$ and in IP 8, 0.6${\mu}{\textrm}{m}$, in IP 10, 0.7${\mu}{\textrm}{m}$, in IP 12, 0.8${\mu}{\textrm}{m}$ higher than before. This figure show the surface roughness is higher than before, because a table move in either X-axis or Y-axis in square hole, on the contrary, in circle there table move in X-axis and Y-axis at the same time. hand drum form getting small when wire tension increase 1000gf to 1500gf, at the same working conditions. The smaller of off time, the maller of hand drum form in same condition and same wire tension. but if you compare square hole with circle hole' graph, hand drum form displayed in maintained term of working condision, on the contrary, in case of square hole variation of hand drum form is more increase than a grow of IP