State of the art electrical discharge machining (EDM)

International Journal of Machine Tools and Manufacture - Tập 43 - Trang 1287-1300 - 2003
K.H Ho1, S.T Newman1
1Advanced Manufacturing Systems and Technology Centre, Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, UK

Tài liệu tham khảo

Kalpajian, 2003, Material removal processes: abrasive, chemical, electrical and high-energy beam, 541 S. Webzell, That first step into EDM, in: Machinery, 159 (4040), Findlay Publications Ltd, Kent, UK, November 2001, p. 41. 1965, History and development, 6 Livshits, 1960, Introduction, x Jameson, 2001, Description and development of electrical discharge machining (EDM), 12 Houman, 1983, Total EDM, 5 Tsai, 2001, Predictions on surface finish in electrical discharge machining based upon neural network models, Int. J. Mach. Tools Manuf., 41, 1385, 10.1016/S0890-6955(01)00028-1 Tsai, 2001, Semi-empirical model of surface finish on electrical discharge machining, Int. J. Mach. Tools Manuf., 41, 1455, 10.1016/S0890-6955(01)00015-3 Jeswani, 1978, Roughness and wear characteristics of spark-eroded surface, Wear, 51, 227, 10.1016/0043-1648(78)90262-4 Thomson, 1989, Surface damage in electrodischarge machining, Mater. Sci. Technol., 5, 1153, 10.1179/mst.1989.5.11.1153 Tsai, 2003, EDM performance of Cr/Cu-based composite electrodes, Int. J. Mach. Tools Manuf., 43, 245, 10.1016/S0890-6955(02)00238-9 Shobert, 1983, What happens in EDM, 3 Boothroyd, 1989, Non-conventional machining processes, 491 McGeough, 1988, Electrodischarge machining, 130 Krar, 1997, Electrical discharge machining, 800 Konig, 1988, EDM—future steps towards the machining of ceramics, Ann. CIRP, 37, 623, 10.1016/S0007-8506(07)60759-8 Puri, 2003, An analysis and optimisation of the geometrical inaccuracy due to wire lag phenomenon in WEDM, Int. J. Mach. Tools Manuf., 43, 151, 10.1016/S0890-6955(02)00158-X Aspinwall, 2001, Hybrid high speed machining (HSM): system design and experimental results for grinding/HSM and EDM/HSM, Ann. CIRP, 50, 145, 10.1016/S0007-8506(07)62091-5 Jia, 1997, Study on a new kind of combined machining technology of ultrasonic machining and electrical discharge machining, Int. J. Mach. Tools Manuf., 37, 193, 10.1016/S0890-6955(96)00048-X Kremer, 1991, A study of the effect of synchronizing ultrasonic vibrations with pulses in EDM, Ann. CIRP, 40, 211, 10.1016/S0007-8506(07)61970-2 Kremer, 1989, Effects of ultrasonic vibrations on the performances in EDM, Ann. CIRP, 38, 199, 10.1016/S0007-8506(07)62684-5 Aspinwall, 1992, Electrical discharge texturing, Int. J. Mach. Tools Manuf., 32, 183, 10.1016/0890-6955(92)90077-T Kozak, 1994, Material removal in EDWM of PCD blanks, J. Eng. Ind. (Trans. ASME), 116, 363, 10.1115/1.2901953 Furutani, 1997, Simultaneous finishing a pair of dies by electrical discharge grinding, 263 Bayramoglu, 1994, Systematic investigation on the use of cylindrical tools for the production of 3D complex shapes on CNC EDM machines, Int. J. Mach. Tools Manuf., 34, 327, 10.1016/0890-6955(94)90003-5 Arthur, 1996, Using rapid prototyping to produce electrical discharge machining electrodes, Rapid Prototyping J., 2, 4, 10.1108/13552549610109036 Weng, 2002, Study of the batch production of micro parts using the EDM process, Int. J. Adv. Manuf. Technol., 19, 266, 10.1007/s001700200033 Rajurkar, 2000, 3D micro-EDM using CAD/CAM, Ann. CIRP, 49, 127, 10.1016/S0007-8506(07)62911-4 Masuzawa, 2000, State of the art of micromachining, Ann. CIRP, 49, 473, 10.1016/S0007-8506(07)63451-9 Masuzawa, 1985, Wire electro-discharge grinding for micro-machining, Ann. CIRP, 34, 431, 10.1016/S0007-8506(07)61805-8 Masuzawa, 1994, A combined electrical machining process for micro nozzle fabrication, Ann. CIRP, 43, 189, 10.1016/S0007-8506(07)62193-3 Yu, 1998, Micro-EDM for three dimensional cavities—development of uniform wear method, Ann. CIRP, 47, 169, 10.1016/S0007-8506(07)62810-8 Yeo, 2001, A feasibility study on the micro electro-discharge machining process for photomask fabrication, Int. J. Adv. Manuf. Technol., 18, 7, 10.1007/PL00003950 Ishida, 2002, L-shaped curved hole creation by means of electrical discharge machining and an electrode curved motion generator, Int. J. Adv. Manuf. Technol., 19, 260, 10.1007/s001700200032 Fukui, 1989, Developing a ‘mole’ electric discharge digging machining, Ann. CIRP, 38, 203, 10.1016/S0007-8506(07)62685-7 Ichiyasu, 1997, Machining curved tunnel for coolant with mole EDM Sanchez, 2001, Development of optimum electrodischarge machining technology for advanced ceramics, Int. J. Adv. Manuf. Technol., 18, 897, 10.1007/PL00003958 Lee, 1998, Machining of engineering ceramics by ultrasonic vibration assisted EDM method, J. Mater. Manuf. Processes, 13, 133, 10.1080/10426919808935224 Firestone, 1988 Mohri, 1996, Assisting electrode method for machining insulating ceramics, Ann. CIRP, 45, 201, 10.1016/S0007-8506(07)63047-9 Mohri, 2002, Some considerations to machining characteristics of insulating ceramics—towards practical use in industry, Ann. CIRP, 51, 161, 10.1016/S0007-8506(07)61490-5 Matsuo, 1992, Investigation on the optimum carbide content and machining condition for wire EDM of zirconia ceramics, Ann. CIRP, 41, 231, 10.1016/S0007-8506(07)61192-5 Yan, 2000, Machining characteristics of Al2O3/6061Al composite using rotary EDM with a disklike electrode, Int. J. Adv. Manuf. Technol., 16, 322, 10.1007/s001700050164 Mamalis, 1992, On the electrodischarge machining of ceramic plasma-sprayed steel plates, Ann. CIRP, 41, 235, 10.1016/S0007-8506(07)61193-7 Muller, 2000, Non-conventional machining of particle reinforced metal matrix composite, Int. J. Mach. Tools Manuf., 40, 1351, 10.1016/S0890-6955(99)00121-2 Soni, 1996, Experimental investigation on migration of material during EDM of die steel (T215 Cr12), J. Mater. Process. Technol., 56, 439, 10.1016/0924-0136(95)01858-1 Roethel, 1976, Contribution to the micro-analysis of the spark eroded surfaces, Ann. CIRP, 25, 135 Erden, 1983, Effect of materials on the mechanism of electric discharge machining (EDM), J. Eng. Mater. Technol., 105, 132, 10.1115/1.3225627 Gangadhar, 1992, Pulse train studies in EDM with controlled pulse relaxation, Int. J. Mach. Tools Manuf., 32, 651, 10.1016/0890-6955(92)90020-H Singh, 1999, A thermo-electric model of material removal during electric discharge machining, Int. J. Mach. Tools Manuf., 39, 669, 10.1016/S0890-6955(98)00047-9 Gadalla, 1989, Machining of WC–Co composites, Mater. Manuf. Processes, 4, 411, 10.1080/10426918908956301 Lee, 1991, Some characteristics of electrical discharge machining of conductive ceramics, Mater. Manuf. Processes, 6, 635, 10.1080/10426919108934794 Bayramoglu, 1995, Manufacturing linear and circular contours using CNC EDM and frame type tools, Int. J. Mach. Tools Manuf., 35, 1125, 10.1016/0890-6955(95)90407-D Saito, 1986, Development of numerical contouring control electrical discharge machining (NCC-EDM), Ann. CIRP, 35, 117, 10.1016/S0007-8506(07)61851-4 Kaneko, 1984, Three dimensionally controlled EDM using cylindrical electrode, J. Japan Soc. Electr. Machining Eng., 18, 1, 10.2526/jseme.18.1 Bleys, 2002, Real-time tool wear compensation in milling EDM, Ann. CIRP, 51, 157, 10.1016/S0007-8506(07)61489-9 Wong, 1986, Electrical discharge machining with transverse tool movement, 10.1007/978-1-349-08114-1_52 Kunieda, 2000, Development of multi-spark EDM, Ann. CIRP, 49, 119, 10.1016/S0007-8506(07)62909-6 Mohri, 1985, Mirror-like finishing by EDM Kunieda, 1991, Improvement of EDM efficiency by supplying oxygen gas into gap, Ann. CIRP, 40, 215, 10.1016/S0007-8506(07)61971-4 Mohri, 1995, Electrode wear process in electrical discharge machining, Ann. CIRP, 44, 165, 10.1016/S0007-8506(07)62298-7 Marafona, 2000, A new method of optimising material removal rate using EDM with copper–tungsten electrodes, Int. J. Mach. Tools Manuf., 40, 153, 10.1016/S0890-6955(99)00062-0 Mohri, 2000, A new process of additive and removal machining by EDM with a thin electrode, Ann. CIRP, 49, 123, 10.1016/S0007-8506(07)62910-2 Snoeys, 1986, Current trends in non-conventional machining techniques, Ann. CIRP, 35, 467, 10.1016/S0007-8506(07)60195-4 Staelens, 1989, A computer integrated machining strategy for planetary EDM, Ann. CIRP, 38, 187, 10.1016/S0007-8506(07)62681-X Dauw, 1986, On the derivation and application of a real-time tool wear sensor in EDM, Ann. CIRP, 35, 111, 10.1016/S0007-8506(07)61850-2 Kunieda, 1996, Electrical discharge machining in gas, Ann. CIRP, 46, 143, 10.1016/S0007-8506(07)60794-X Dauw, 1988, Geometrical simulation of the EDM die-sinking process, Ann. CIRP, 37, 191, 10.1016/S0007-8506(07)61616-3 Kunieda, 1998, Simulation of die-sinking EDM by discharge location searching algorithm, Int. J. Electr. Machining, 3, 79, 10.2526/ijem.3.79 Kunieda, 1999, Reverse simulation of die-sinking EDM, Ann. CIRP, 48, 115, 10.1016/S0007-8506(07)63144-8 Lee, 1988, Quantification of surface damage of tool steels after EDM, Int. J. Mach. Tools Manuf., 28, 359, 10.1016/0890-6955(88)90050-8 Lee, 1990, Towards a better understanding of the surface features of electro-discharge machined tool steels, J. Mater. Process. Technol., 24, 513, 10.1016/0924-0136(90)90212-D Lim, 1991, Solidification microstructure of electrodischarge machined surfaces of tool steels, Mater. Sci. Technol., 7, 239, 10.1179/mst.1991.7.3.239 Pandey, 1986, Plasma channel growth and the resolidified layer in EDM, Precision Eng., 8, 104, 10.1016/0141-6359(86)90093-0 Lin, 2001, Surface improvement using a combination of electrical discharge machining with ball burnish machining based on the Taguchi method, Int. J. Adv. Manuf. Technol., 18, 673, 10.1007/s001700170028 Abu Zeid, 1997, On the effect of electro-discharge machining parameters on the fatigue life of AISI D6 tool steel, J. Mater. Process. Technol., 68, 27, 10.1016/S0924-0136(96)02523-X Kruth, 1995, Study of the white layer of a surface machined by die-sinking electro-discharge machining, Ann. CIRP, 44, 169, 10.1016/S0007-8506(07)62299-9 Ayers, 1984, Formation of metal carbide powder by spark machining of reactive metals, Metal. Trans. A, 15A, 1117, 10.1007/BF02644706 Gangadhar, 1991, Surface modification in electrodischarge processing with a powder compact tool electrode, Wear, 143, 45, 10.1016/0043-1648(91)90084-8 Mohri, 1993, Metal surface modification by electrical discharge machining with composite electrode, Ann. CIRP, 42, 219, 10.1016/S0007-8506(07)62429-9 Tsuekawa, 1994, Surface modification of aluminium by electrical discharge alloying, Mater. Sci. Eng., A174, 193, 10.1016/0921-5093(94)91088-X Samuel, 1997, Power metallurgy tool electrodes for electrical discharge machining, Int. J. Mach. Tools Manuf., 37, 1625, 10.1016/S0890-6955(97)00006-0 Simao, 2003, Workpiece surface modification using electrical discharge machining, Int J. Mach. Tools Manuf., 43, 121, 10.1016/S0890-6955(02)00187-6 Hassan, 1997, An investigation into the surface characteristics of burnished cast Al–Cu alloys, Int. J. Mach. Tools Manuf., 37, 813, 10.1016/S0890-6955(96)00058-2 Hassan, 1997, The effect of ball- and roller-burnishing on the surface roughness and hardness of some non-ferrous metals, J. Mater. Process. Technol., 72, 385, 10.1016/S0924-0136(97)00199-4 Loh, 1993, Application of experimental design in ball burnishing, Int. J. Mach. Tools Manuf., 33, 841, 10.1016/0890-6955(93)90041-R Loh, 1988, Effects of ball burnishing parameters on surface finish—a literature survey and discussion, Precision Eng., 10, 215, 10.1016/0141-6359(88)90056-6 Yan, 2000, Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite, Int. J. Mach. Tools Manuf., 40, 1403, 10.1016/S0890-6955(00)00005-5 Schumacher, 1990, About the role of debris in the gap during electrical discharge machining, Ann. CIRP, 39, 197, 10.1016/S0007-8506(07)61034-8 Tzeng, 2001, Effects of powder characteristics on electrodischarge machining efficiency, Int. J. Adv. Manuf. Technol., 17, 586, 10.1007/s001700170142 Jeswani, 1981, Effect of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining, Wear, 70, 133, 10.1016/0043-1648(81)90148-4 Mohri, 1991, A new process of finish machining on free surface by EDM methods, Ann. CIRP, 40, 207, 10.1016/S0007-8506(07)61969-6 Quan, 1995, Powder-suspension dielectric fluid for EDM, J. Mater. Process. Technol., 52, 44, 10.1016/0924-0136(94)01442-4 Luo, 1997, The dependence of interspace discharge transitivity upon the gap debris in precision electro-discharge machining, J. Mater. Process. Technol., 68, 121, 10.1016/S0924-0136(96)00019-2 Zhang, 1997, Study on the electro-discharge machining of a hot pressed aluminium oxide based ceramic, J. Mater. Process. Technol., 63, 908, 10.1016/S0924-0136(96)00012-X Lin, 2002, Optimisation of the EDM process based on the orthogonal array with fuzzy logic and grey relational analysis method, Int. J. Adv. Manuf. Technol., 19, 271, 10.1007/s001700200034 Lin, 2000, Optimization of the electrical discharge machining process based on the Taguchi method with fuzzy logics, J. Mater. Process. Technol., 102, 48, 10.1016/S0924-0136(00)00438-6 Tzeng, 2003, A simple approach for robust design of high-speed electrical discharge machining technology, Int. J. Mach. Tools Manuf., 43, 217, 10.1016/S0890-6955(02)00261-4 Cogun, 1990, A technique and its applications for evaluation of material removal contributions of pulses in electrical discharge machining, Int. J. Mach. Tools Manuf., 30, 19, 10.1016/0890-6955(90)90038-K Kao, 1997, A neutral-network approach for the on-line monitoring of the electrical discharge machining process, J. Mater. Process. Technol., 69, 112, 10.1016/S0924-0136(97)00004-6 Liu, 1997, Monitoring of the electrical discharge machining process by abductive networks, Int. J. Adv. Manuf. Technol., 13, 264, 10.1007/BF01179608 Weck, 1992, Analysis and adaptive control of EDM sinking process using the ignition delay time and fall time as parameter, Ann. CIRP, 41, 243, 10.1016/S0007-8506(07)61195-0 Rajurkar, 1989, A new model reference adaptive control of EDM, Ann. CIRP, 38, 183, 10.1016/S0007-8506(07)62680-8 Snoeys, 1980, Improved adaptive control system for EDM processes, Ann. CIRP, 29, 97, 10.1016/S0007-8506(07)61302-X Dauw, 1983, Advanced pulse discriminating system for EDM process analysis and controls, Ann. CIRP, 32, 541, 10.1016/S0007-8506(07)60181-4 Yu, 2001, Waveform monitoring of electrical discharge machining by wavelet transform, Int. J. Adv. Manuf. Technol., 17, 339, 10.1007/s001700170168 Wang, 1995, Digital gap monitor and adaptive integral control for auto-jumping in EDM, J. Eng. Ind., 117, 253, 10.1115/1.2803302 Rajurkar, 1990, Real-time stochastic model and control of EDM, Ann. CIRP, 39, 187, 10.1016/S0007-8506(07)61032-4 Boccadoro, 1995, About the application of fuzzy controllers in high-performance die-sinking EDM machines, Ann. CIRP, 44, 147, 10.1016/S0007-8506(07)62294-X Tarng, 1997, A fuzzy pulse discriminating system for electrical discharge machining, Int. J. Mach. Tools Manuf., 37, 511, 10.1016/S0890-6955(96)00033-8 Tarng, 1996, Genetic synthesis of a fuzzy pulse discriminator in electrical discharge machining, J. Intell. Manuf., 7, 311, 10.1007/BF00124831 Bhattacharyya, 1978, Monitoring the EDM process by radio signals, Int. J. Prod. Res., 16, 353, 10.1080/00207547808930027 Bhattacharyya, 1980, Monitoring and controlling the EDM process, J. Eng. Ind., 102, 189, 10.1115/1.3183853 Rajurkar, 1997, Improvement of EDM performance with advanced monitoring and control system, J. Manuf. Sci. Eng., 119, 770, 10.1115/1.2836823 Lonardo, 1999, Effect of flushing and electrode material on die sinking EDM, Ann. CIRP, 48, 123, 10.1016/S0007-8506(07)63146-1 Wong, 1995, Effects of flushing on electro-discharge machined surfaces, J. Mater. Process. Technol., 48, 299, 10.1016/0924-0136(94)01662-K 1982 Kagaya, 1986, Micro-electrodischarge machining using water as a working fluid—I: micro-hole drilling, Precision Eng., 8, 157, 10.1016/0141-6359(86)90034-6 Benedict, 1987, Electrical discharge machining (EDM), 211 Masuzawa, 1992, Improved jet flushing for EDM, Ann. CIRP, 41, 239, 10.1016/S0007-8506(07)61194-9 Masuzawa, 1983, A self-flushing method with spark-erosion machining, Ann. CIRP, 32, 109, 10.1016/S0007-8506(07)63372-1 De Bruijn, 1978, Effect of a magnetic field on the gap cleaning in EDM, Ann. CIRP, 27, 93 Enache, 1990, The study of EDM with forced vibration of tool electrode, Ann. CIRP, 39, 167, 10.1016/S0007-8506(07)61027-0 Murti, 1986, A comparative analysis of machining characteristics in ultrasonic assisted EDM by the response surface methodology, Int. J. Prod. Res., 25, 259, 10.1080/00207548708919838 Guu, 2001, Effects of workpiece rotation on machinability during electrical discharge machining, J. Mater. Manuf. Processes, 16, 91, 10.1081/AMP-100103699 Kunieda, 1988, A fundamental study on a horizontal EDM, Ann. CIRP, 37, 187, 10.1016/S0007-8506(07)61615-1 Masuzawa, 2002, EDM-lathe for micromachining, Ann. CIRP, 51, 355, 10.1016/S0007-8506(07)61535-2 Mohri, 1989, Drilling of deep microholes by EDM, Ann. CIRP, 38, 195, 10.1016/S0007-8506(07)62683-3 Sato, 1986, The development of an electrodischarge machine for micro-hole boring, Precision Eng., 8, 163, 10.1016/0141-6359(86)90035-8 Soni, 1994, Microanalysis of debris formed during rotary EDM of titanium alloy (Ti 6Al 4V) and die steel (T 215 Cr12), Wear, 177, 71, 10.1016/0043-1648(94)90119-8 Soni, 1994, Machining characteristics of titanium with rotary electro-discharge machining, Wear, 171, 51, 10.1016/0043-1648(94)90347-6 Enache, 1993, Dynamic stability of the technological machining system in EDM, Ann. CIRP, 42, 209, 10.1016/S0007-8506(07)62427-5 Ding, 2000, A computer-aided EDM electrode design system for mold manufacturing, Int. J. Prod. Res., 38, 3079, 10.1080/00207540050117459 Kruth, 1986, Steps towards an integrated CAD/CAM system for mould design and manufacture: anisotropic shrinkage, component library and link to NC machining and EDM, Ann. CIRP, 35, 83, 10.1016/S0007-8506(07)61844-7 Lauwers, 1994, Computer-aided process planning for EDM operations, J. Manuf. Syst., 13, 313, 10.1016/0278-6125(94)P2581-X Yeo, 1999, A method for green process planning in electric discharge machining, Int. J. Adv. Manuf. Technol., 15, 287, 10.1007/s001700050068 DeVries, 1990, Integration of EDM within a CIM environment, Ann CIRP, 39, 665, 10.1016/S0007-8506(07)63003-0 Tay, 2001, The potential of plating techniques in the development of rapid EDM tooling, Int. J. Adv. Manuf. Technol., 18, 892, 10.1007/PL00003957 Yang, 1999, Integration of rapid prototyping and electroforming for tooling applications, Ann. CIRP, 48, 119, 10.1016/S0007-8506(07)63145-X Arthur, 1998, The measurement of heat distribution in stereolithography electrodes during electro-discharge machining, Int. J. Prod. Res., 36, 2451, 10.1080/002075498192625 Durr, 1999, Rapid tooling of EDM electrodes by means of selective laser sintering, Comput. Ind., 39, 35, 10.1016/S0166-3615(98)00123-7 Pandit, 1987, Verification of on-line computer control of EDM by data dependent systems, J. Eng. Ind., 109, 109, 10.1115/1.3187100 Semon, 1975 Stovicek, 1993, The state-of-the-art EDM science, 42 Taylan, 2001, Manufacturing of dies and molds, Ann. CIRP, 50, 405