Wire Vibration Modeling and Experimental Analysis for Wire Saw Machining

2019 ◽  
Vol 141 (12) ◽  
Author(s):  
Aofei Tang ◽  
Shujuan Li ◽  
Guigeng Yang ◽  
Lun Li ◽  
Robert G. Landers
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Feed Rate ◽  
Processing Time ◽  
Experimental Studies ◽  
Wire Tension ◽  
Wire Saw ◽  
Part Surface ◽  
Wire Vibration ◽  
The Wire

Abstract Surface roughness is the key index point of wire saw processing silicon carbide (SiC). Many factors influence wafer surface quality, which is determined by the motion of the wire relative to the part. The vibration characteristic of wire saw and the process parameters are concerned factors in this paper, which presents a wire vibration model to study the wire saw vibration law. Experimental studies of a stationary wire are conducted to calibrate the damping coefficient and experimental studies of a moving wire are used to validate the developed model. Simulation, theoretical, and experimental data for wire vibrations during a variety of machining processes are found to compare very well, and the effects of various wire saw process parameters are investigated to analyze the influences of process parameters on wire vibration. It was shown that increasing the wire tension and feed rate, or decreeing the wire length, decreases the wire's first dominant frequency, and that changes in the wire velocity had a negligible effect. Finally, the measurement of the surface morphology and wire saw vibrations for different processing parameters was conducted, and it was seen that increases in the wire velocity and wire tension increases part surface quality and decreases processing time, while an increase in the feed rate decreases both part surface quality and processing time. The results show a clear correlation between the amplitude of the wire vibration outside of the processing zone and the part surface quality.

Study on Modeling and Simulation of Wire Vibration in WEDM

2012 ◽  
Vol 472-475 ◽  
pp. 2013-2017
Author(s):  
Chao Jiang Li ◽  
Yong Feng Guo ◽  
Ji Cheng Bai ◽  
Ze Sheng Lu ◽  
Chuan Chen
Keyword(s):  
Electrical Discharge ◽  
Pulse Width ◽  
Metal Cutting ◽  
Electrical Discharge Machining ◽  
Orthogonal Design ◽  
Pulse Interval ◽  
Machining Accuracy ◽  
Wire Tension ◽  
Wire Vibration ◽  
The Wire

The wire electrical discharge machining (WEDM) has been widely used in the field of metal cutting, mold industry, aerospace and so on. However, in the discharge machining, it is very important to restrain the wire-tool vibration for the improvement of machining accuracy. In this paper, it is created a model of the wire vibration with double-ended fixed, established the differential equation of vibration, and derived its full theoretical solution to analysis the vibration factors. Simulations of the wire vibration with ANSYS Transient dynamics analysis were given. An orthogonal design of the wire vibration using L9 orthogonal table was made, and the experiment found that minimize the servo voltage, reduce the pulse width, and select the appropriate wire tension and pulse interval, which can reduce the wire vibration.

Study on Electroplated Diamond Wire Saw Development and Wire Saw Wear Analysis

2009 ◽  
Vol 416 ◽  
pp. 311-315 ◽  
Author(s):  
Pei Qi Ge ◽  
Yu Fei Gao ◽  
Shao Jie Li ◽  
Zhi Jian Hou
Keyword(s):  
Current Density ◽  
High Performance ◽  
Experimental Studies ◽  
Cathode Current Density ◽  
Diamond Wire ◽  
Wire Saw ◽  
Diamond Wire Saw ◽  
Cathode Current ◽  
The Wire ◽  
Electroplating Process

Development of high performance diamond impregnated wire is the key of application for fixed-abrasive wire sawing technology. In this paper, some experimental studies were done for development of electroplated diamond wire saw by employing the bright nickel bath. The wire saw electroplating process was developed, the effects of cathode current density and time at tack-on stage on diamond grits density and adhesion between saw matrix and plating coating were discussed. The wire saw cutting experiments were carried out for analysis the used wire wear using the scanning electron microscope (SEM). The experimental results show the optimum tack-on current density to obtain the wire saw with good abrasive distribution and adhesion is 1.5~2.0A/dm2, and the time of pre-plating, tack-on and buildup is 6, 8~10 and 18min in turn. Diamond wire saw wear includes coating wear and grain-abrasion, and the primary wear form is grits pulled-out.

Preparation of parts for coating by granular abrasive media treatment

2020 ◽  
pp. 416-419
Author(s):  
M.A. Tamarkin ◽  
E.E. Tishchenko ◽  
V.M. Troitsky ◽  
A.A. Mordovtsev
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Processing Time ◽  
Quality Parameters ◽  
Technological Operation ◽  
Design Technique ◽  
Part Surface ◽  
Medium Particle

The formation of surface quality parameters of parts treated in granular abrasive media, on the surface of which it is necessary to apply coatings is study. Parameters of trace are determined during interaction of medium particle with part surface. Dependencies for calculating of surface roughness and processing time are established. The design technique of technological operation for preparation of part for coating is described.

Force Modeling and Control of SiC Monocrystal Wafer Processing

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Shujuan Li ◽  
Siming Du ◽  
Aofei Tang ◽  
Robert G. Landers ◽  
Yang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Control Variable ◽  
Contact Length ◽  
Machining Process ◽  
Model Parameters ◽  
Wire Saw ◽  
The Wire

Wire saws with fixed diamond abrasive are often used to cut hard and brittle materials owning to the wire saw's narrow kerf, low cutting force, and minimal material waste. Typically, the cutting force changes during the operation since the part diameter and the contact length between the wire saw and part (i.e., contact length) continuously change, even if the process parameters (i.e., wire saw velocity, part feed rate, part rotation speed, and wire saw tension) are fixed, leading to wire saw breakage, wafer collapse, and inferior surface roughness. This study addresses this issue by regulating the force via feedback control. The most significant process parameter affecting the normal force, namely, part feed rate, is taken as the control variable. A system identification routine is used to obtain the transfer function relating the normal force and commanded part feed rate and the model parameters are identified online. An adaptive force controller is designed, and simulation and experimental studies for SiC monocrystal wafer wire saw machining are conducted. The results show the dynamic model well characterizes the normal force generated when wire saw machining SiC monocrystal, and the adaptive controller can effectively track various normal reference force trajectories (i.e., constants, ramps, and sine waves). The experimental results demonstrate that the wire saw machining process with adaptive force control can improve the cutting productivity and significantly decrease wafer surface roughness as compared to the cutting process with a constant part feed rate.

A Preliminary Numerical Study of the Slurry Wire Sawing Process

2012 ◽  
Author(s):  
Chunhui Chung
Keyword(s):  
Steady State ◽  
Numerical Study ◽  
Semiconductor Wafer ◽  
Steady State Condition ◽  
Local Loads ◽  
Wire Tension ◽  
Wire Saw ◽  
Simulation Results ◽  
The Wire ◽  
Sawing Process

Slurry wire saw has been utilized to slice the brittle semiconductor wafer substrates for over 20 years. However, the complicated slicing process limits the further studies and advances of this exclusive slicing tool for big wafers. In this study, a numerical model of the slurry wire sawing process was developed based on the mechanism of brittle indentation cracks. The simulation results illustrate how the factors such as wire speed, wire tension, and feed rate of the ingot affect the slicing conditions including the bow angles of the wire and the local normal loads on both the workpiece and the wire. In addition, the results show that the steady-state condition would be reached via overshooting or non-overshooting approach based on the slicing parameters. A higher wire speed is suggested to reduce the bow angles and local loads during slicing process. However, the limitation of the wire speed depends on the material of the wire and the specification of the wire saw machine.

scholarly journals PSI and TOPSIS Based Selection of Process Parameters in WEDM

2017 ◽  
Vol 61 (4) ◽  
pp. 255 ◽  
Author(s):  
Sunny Diyaley ◽  
Pramod Shilal ◽  
Ishwer Shivakoti ◽  
Ranjan Kumar Ghadai ◽  
Kanak Kalita
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Machining Process ◽  
Wire Tension ◽  
Input Parameters ◽  
The Wire ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Wire electric discharge machining (WEDM) is a nontraditional machining process for machining conductive materials with complex and intricate shapes with a high surface finish and dimensional accuracy. The decision making for the selection of the best set of combinations of input process parameters is a major challenge. Therefore a proper optimization tool should be used for the optimal selection of process parameters. The resent work deals with the comparative study of Preferential Selection Index (PSI) and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) for the selection of process parameters during machining of EN31 tool steel. Four input parameters- Pulse on Time (Ton ), Pulse off Time (Toff  ), Servo Voltage (SV) and the Wire tension (WT) are considered. Surface roughness and material removal rate are the measured output responses. Taguchi L9 orthogonal array is used for developing the experimental design. Three levels of each control factor are considered. The results show that a single parameter alone does not have a significant influence on the output responses. Thequality of the output responses depends on the combination of the various set of input parameters. The best set of combination suggested from the current input parameters for machining of EN31 Tool Steel by Wire EDM Process is found to be Pulse on Time (Ton )= 15μs, Pulse Off Time (Toff  )=35μs, Servo Voltage (SV)=40V and the Wire tension (WT)=5kgf from both PSI as well as TOPSIS techniques. Confirmation experiments are performed to validate the optimal results.

scholarly journals Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 903
Author(s):  
Adel T. Abbas ◽  
Saqib Anwar ◽  
Elshaimaa Abdelnasser ◽  
Monis Luqman ◽  
Jaber E. Abu Qudeiri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Surface Quality ◽  
Process Parameters ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Machined Surface ◽  
Cooling Strategies ◽  
Dry Conditions

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

scholarly journals The effects of the process parameters in electrochemical machining on the surface quality

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Nguyen Thi Bich Nhung ◽  
Dao Thanh Liem ◽  
Truong Quoc Thanh
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Electrode Gap

Based on the number of previous studies, this study aims to investigate the effects of process parameters of an Electrochemical Machining process, which are electrolyte concentration, the voltage applied to the machine, feed rate of the electrode, and Inter-Electrode Gap between tool and workpiece. Aluminum samples of 25 mm diameter x 25 mm height and 30mm diameter x 25mm height of the tool is made up of copper with a circular cross-section with 2 mm internal hole. The design of the system is based on the Taguchi method. Here, the signal-to-noise (S/N) model, the analysis of variance (ANOVA) and regression analyses are applied to determine optimal levels and to investigate the effects of these parameters on surface quality. Finally, the experiments that use the optimal levels of machining parameters are conducted to verify the effects of the process parameters on the surface quality of the products. The results pointed out a set of optimal parameters of the ECM process. The Inter-Electrode Gap between the tool and workpiece has extremely effected on these Material Removal rates and surface roughness. The Material Removal Rate increases with diseases in Inter-Electrode Gap, and Ra diseases with diseases in Inter-Electrode Gap. The experimental results show that maximum Material Removal Rate has obtained with electrolyte concentration at 100 g/l, feed rate at 0.0375 mm/min, the voltage at 15V, and Inter-Electrode Gap at 0.5mm. The minimum Ra has obtained with electrolyte concentration at 80 g/l, feed rate at 0.0468 mm/min, the voltage at 10V, and Inter-Electrode Gap at 0.5mm. This result has led to need studies on these parameters in Electrochemical Machining, which are improving productivities and surface roughness of the products.   

Theoretical Research on Contact Length in the Rocking Motion Wire Saw

2016 ◽  
Vol 1136 ◽  
pp. 343-349 ◽  
Author(s):  
Hui Huang ◽  
Sheng Long Zheng ◽  
Xi Peng Xu
Keyword(s):  
Line Segment ◽  
Feed Rate ◽  
Contact Length ◽  
Theoretical Research ◽  
Theoretical Equation ◽  
Motion Path ◽  
Wire Saw ◽  
Rocking Motion ◽  
The Wire ◽  
Wire Motion

Rocking motion wire saw with the additional rocking motion of either the wire or the workpiece is a new machining method compared with the traditional wire saw. The length of contact between the wire and the workpiece changes in this new saw process. In this paper, the wire motion and the contact length were theoretically researched. Wire motion path equation with the rocking motion was established. The theoretical equation of the contact length in half a swing period was derived out. The results indicated that the wire motion was a single pendulum movement with a length line segment, which the swing pivot was moved with a feed rate. The contact length had significant changes in half a swing period in the rocking motion wire saw. The contact length varied periodically with the same amplitude in the square ingot sawing, which varied periodically with the variation amplitude in the circle ingot sawing. The contact length with the rocking motion was obviously shorter than the case without the rocking motion for either the square ingot or the circle ingot.

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