Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms

Scott F. Miller; Enhui Shi; Chen C. Kao; Albert J. Shih; Jun Qu

doi:10.1115/IMECE2004-60894

Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms

Scott F. Miller, Enhui Shi, Chen C. Kao, Albert J. Shih, Jun Qu

Surface Engineering and Tribology

Research output: Contribution to conference › Paper › peer-review

2 Scopus citations

Abstract

The wire electrical discharge machining (EDM) of crosssection with minimum thickness and compliant mechanisms are studied. Effects of EDM process parameters, particularly the spark cycle time and spark on-time on thin cross-section cutting of Nd-Fe-B magnetic material, carbon bipolar plate, and titanium are investigated. An envelope of feasible wire EDM process parameters is generated for Ti. The application of such envelope to select suitable EDM process parameters for micro feature generation is demonstrated. Scanning Electron Microscopy (SEM) analysis of EDM surface, subsurface, and debris are presented. SEM observations lead to a hypothesis based on the thermal and electrostatic stress induced fracture to explain the limiting factor for wire EDM cutting of thin-sections. Applications of the thin cross-section cutting for EDM compliant mechanisms are discussed.

Original language	English
Pages	165-171
Number of pages	7
DOIs	https://doi.org/10.1115/IMECE2004-60894
State	Published - 2004
Event	2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004 - Anaheim, CA, United States Duration: Nov 13 2004 → Nov 19 2004

Conference

Conference	2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004
Country/Territory	United States
City	Anaheim, CA
Period	11/13/04 → 11/19/04

Funding

The authors acknowledge Magnequench and Dr B.M. Ma for the sintered Nd–Fe–B permanent magnets, Porvair PLC, Dr K. Butcher for the metal foam and carbon–carbon bipolar plate, Dr S. Kota on the design specification of compliant mechanisms, Enhui Shi for machine operation, and Rui Li for finite element analysis. A portion of this research was sponsored by the Assistant Secretary for Energy Efficiency and Renewable Energy, Office of Transportation Technologies, as part of the High Temperature Materials Laboratory User Program, Oak Ridge National Laboratory, managed by UT-Battelle, LLC for the U.S. Department of Energy under contract number DE-AC05-00OR22725.

Funders	Funder number
Office of Transportation Technologies
U.S. Department of Energy	DE-AC05-00OR22725
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory
UT-Battelle

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1115/IMECE2004-60894

Cite this

@conference{2696326f3ff14d1dacc51cfedcaaeb2e,

title = "Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms",

abstract = "The wire electrical discharge machining (EDM) of crosssection with minimum thickness and compliant mechanisms are studied. Effects of EDM process parameters, particularly the spark cycle time and spark on-time on thin cross-section cutting of Nd-Fe-B magnetic material, carbon bipolar plate, and titanium are investigated. An envelope of feasible wire EDM process parameters is generated for Ti. The application of such envelope to select suitable EDM process parameters for micro feature generation is demonstrated. Scanning Electron Microscopy (SEM) analysis of EDM surface, subsurface, and debris are presented. SEM observations lead to a hypothesis based on the thermal and electrostatic stress induced fracture to explain the limiting factor for wire EDM cutting of thin-sections. Applications of the thin cross-section cutting for EDM compliant mechanisms are discussed.",

author = "Miller, {Scott F.} and Enhui Shi and Kao, {Chen C.} and Shih, {Albert J.} and Jun Qu",

year = "2004",

doi = "10.1115/IMECE2004-60894",

language = "English",

pages = "165--171",

note = "2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004 ; Conference date: 13-11-2004 Through 19-11-2004",

}

TY - CONF

T1 - Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms

AU - Miller, Scott F.

AU - Shi, Enhui

AU - Kao, Chen C.

AU - Shih, Albert J.

AU - Qu, Jun

PY - 2004

Y1 - 2004

N2 - The wire electrical discharge machining (EDM) of crosssection with minimum thickness and compliant mechanisms are studied. Effects of EDM process parameters, particularly the spark cycle time and spark on-time on thin cross-section cutting of Nd-Fe-B magnetic material, carbon bipolar plate, and titanium are investigated. An envelope of feasible wire EDM process parameters is generated for Ti. The application of such envelope to select suitable EDM process parameters for micro feature generation is demonstrated. Scanning Electron Microscopy (SEM) analysis of EDM surface, subsurface, and debris are presented. SEM observations lead to a hypothesis based on the thermal and electrostatic stress induced fracture to explain the limiting factor for wire EDM cutting of thin-sections. Applications of the thin cross-section cutting for EDM compliant mechanisms are discussed.

AB - The wire electrical discharge machining (EDM) of crosssection with minimum thickness and compliant mechanisms are studied. Effects of EDM process parameters, particularly the spark cycle time and spark on-time on thin cross-section cutting of Nd-Fe-B magnetic material, carbon bipolar plate, and titanium are investigated. An envelope of feasible wire EDM process parameters is generated for Ti. The application of such envelope to select suitable EDM process parameters for micro feature generation is demonstrated. Scanning Electron Microscopy (SEM) analysis of EDM surface, subsurface, and debris are presented. SEM observations lead to a hypothesis based on the thermal and electrostatic stress induced fracture to explain the limiting factor for wire EDM cutting of thin-sections. Applications of the thin cross-section cutting for EDM compliant mechanisms are discussed.

UR - http://www.scopus.com/inward/record.url?scp=23244457252&partnerID=8YFLogxK

U2 - 10.1115/IMECE2004-60894

DO - 10.1115/IMECE2004-60894

M3 - Paper

AN - SCOPUS:23244457252

SP - 165

EP - 171

T2 - 2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004

Y2 - 13 November 2004 through 19 November 2004

ER -

Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms

Abstract

Conference

Funding

UN SDGs

Access to Document

Other files and links

Fingerprint

Cite this