M. Yamazaki, T. Suzuki, N. Mori, Y. Teranishi, M. Kunieda
We describe the limit of miniaturization in micro-electrical discharge machining (EDM) using self-drilled holes. By this method, a microrod is machined using the edge of a hole drilled beforehand by the rod itself in the same setup. Hence, microrods can be machined very precisely without special equipment. To further decrease the minimum machinable diameter of microrods, the single-step forming method, double forming method, spark-out forming method, and step forming method were proposed. The minimum diameter was obtained by the single-step forming method. The straightest microrods were formed by the spark-out forming method.
{"title":"Minimum Diameter of Microrods Machined by Micro-electrical Discharge Machining using Self-Drilled Holes Method","authors":"M. Yamazaki, T. Suzuki, N. Mori, Y. Teranishi, M. Kunieda","doi":"10.2526/JSEME.42.51","DOIUrl":"https://doi.org/10.2526/JSEME.42.51","url":null,"abstract":"We describe the limit of miniaturization in micro-electrical discharge machining (EDM) using self-drilled holes. By this method, a microrod is machined using the edge of a hole drilled beforehand by the rod itself in the same setup. Hence, microrods can be machined very precisely without special equipment. To further decrease the minimum machinable diameter of microrods, the single-step forming method, double forming method, spark-out forming method, and step forming method were proposed. The minimum diameter was obtained by the single-step forming method. The straightest microrods were formed by the spark-out forming method.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2008-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129905192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"多結晶ダイヤモンド焼結体の放電加工への応用に関する研究（第1報） - 各種ダイヤモンド基複合電極による放電加工 -","authors":"佐野 定男, 岩井 学, 植松 哲太郎, 鈴木 清","doi":"10.2526/JSEME.42.65","DOIUrl":"https://doi.org/10.2526/JSEME.42.65","url":null,"abstract":"","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"64 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2008-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121733528","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"ワイヤ放電加工用高性能ワイヤ電極の開発に関する研究（第２報） －直径50μmコーティングワイヤの放電加工特性－","authors":"晃 岡田, 俊之 山内, 公彦 有園, 敏明 清水, 義幸 宇野","doi":"10.2526/JSEME.42.12","DOIUrl":"https://doi.org/10.2526/JSEME.42.12","url":null,"abstract":"","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"22 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2008-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123635214","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Micromachining technologies have been developed to enhance functionality in limited space and to save materials and energy. Micro-electrical discharge machining (EDM) is one of the micro processing methods. The machining efficiency, however, decreases as hole depth increases because the discharge phenomena become unstable owing to sludge stagnation. In this paper, we propose a new EDM method that applies ultrasonic vibration in machining fluid. Cavitation generated in a hole does not only break down air bubbles in EDM but also quickens the sludge removal. The EDM characteristics in terms of parameters such as machining rate, aspect ratio, and hole appearance are investigated in comparison with those of conventional EDM. The machining rate and aspect ratio rise by a factor of about 2 and the electrode wear ratio is about 2/3 the conventional value in the micro-EDM of sintered carbide.
{"title":"放電加工における加工液超音波振動援用の効果(第1報) : 超音波振動援用微細穴あけ加工に関する研究","authors":"小川 仁, 板東 和宏, 常本 佳生","doi":"10.2526/JSEME.41.163","DOIUrl":"https://doi.org/10.2526/JSEME.41.163","url":null,"abstract":"Micromachining technologies have been developed to enhance functionality in limited space and to save materials and energy. Micro-electrical discharge machining (EDM) is one of the micro processing methods. The machining efficiency, however, decreases as hole depth increases because the discharge phenomena become unstable owing to sludge stagnation. In this paper, we propose a new EDM method that applies ultrasonic vibration in machining fluid. Cavitation generated in a hole does not only break down air bubbles in EDM but also quickens the sludge removal. The EDM characteristics in terms of parameters such as machining rate, aspect ratio, and hole appearance are investigated in comparison with those of conventional EDM. The machining rate and aspect ratio rise by a factor of about 2 and the electrode wear ratio is about 2/3 the conventional value in the micro-EDM of sintered carbide.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"51 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2007-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124891650","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
T. Yamauchi, A. Okada, M. Morita, Toshiaki Shimizu, Y. Uno
In this study, we aim to develop a new coating wire electrode for a high-performance wire EDM instead of conventional wires. The effects of coating materials on the fundamental machining characteristics are investigated to obtain the optimum structure, using a high-tensile steel wire coated with brass and zinc whose diameter is 200μm. The experimental results showed that the removal rate increased with the thickness of the coated brass on the steel wire in WEDM with the brass and zinc coated steel wire. The SEM observation and the element analysis of wires after machining clearly showed that the coated brass layer was easily removed when the thickness was small, and a high tension could be loaded during machining when the thickness of the coated brass was sufficiently large to maintain a stable machining performance. Furthermore, the effect of zinc coating on the removal rate was marked when the thickness of the coated brass was relatively small.
{"title":"ワイヤ放電加工用高性能ワイヤ電極の開発に関する研究(第1報)―コーティングワイヤの基礎的加工特性―","authors":"T. Yamauchi, A. Okada, M. Morita, Toshiaki Shimizu, Y. Uno","doi":"10.2526/JSEME.39.92_28","DOIUrl":"https://doi.org/10.2526/JSEME.39.92_28","url":null,"abstract":"In this study, we aim to develop a new coating wire electrode for a high-performance wire EDM instead of conventional wires. The effects of coating materials on the fundamental machining characteristics are investigated to obtain the optimum structure, using a high-tensile steel wire coated with brass and zinc whose diameter is 200μm. The experimental results showed that the removal rate increased with the thickness of the coated brass on the steel wire in WEDM with the brass and zinc coated steel wire. The SEM observation and the element analysis of wires after machining clearly showed that the coated brass layer was easily removed when the thickness was small, and a high tension could be loaded during machining when the thickness of the coated brass was sufficiently large to maintain a stable machining performance. Furthermore, the effect of zinc coating on the removal rate was marked when the thickness of the coated brass was relatively small.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"122 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2005-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121915388","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"電気加工ビギナーのためのリレー講義(その2) : 電磁ノイズと信号計測","authors":"仁田 周一","doi":"10.2526/JSEME.39.90_62","DOIUrl":"https://doi.org/10.2526/JSEME.39.90_62","url":null,"abstract":"","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"123 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2005-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132387029","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper describes the influence of oscillation of gap length on gap phenomena in dry-WEDM. Dry-WEDM was found to have the problem that lower material removal rate than conventional WEDM because of frequent occurrence of short circuiting resulting from the narrower discharge gap length. Since the material removal rate depends on the normal discharge frequency, the gap length was altered periodically using a piezoelectric actuator to obtain the relation between the gap length and normal discharge frequency. It was found that: 1) Fluctuation of total discharge frequency corresponding to the change in gap length is larger in dry-WEDM than that in conventional WEDM because of the narrower gap length in dry-WEDM. 2) Since the short circuiting rate is high in dry-WEDM, the normal discharge frequency is one third of conventional WEDM.
{"title":"Understanding Dry-WEDM Phenomena Through Periodic Oscillation of Discharge Gap","authors":"C. Furudate, M. Kunieda","doi":"10.2526/JSEME.38.89_18","DOIUrl":"https://doi.org/10.2526/JSEME.38.89_18","url":null,"abstract":"This paper describes the influence of oscillation of gap length on gap phenomena in dry-WEDM. Dry-WEDM was found to have the problem that lower material removal rate than conventional WEDM because of frequent occurrence of short circuiting resulting from the narrower discharge gap length. Since the material removal rate depends on the normal discharge frequency, the gap length was altered periodically using a piezoelectric actuator to obtain the relation between the gap length and normal discharge frequency. It was found that: 1) Fluctuation of total discharge frequency corresponding to the change in gap length is larger in dry-WEDM than that in conventional WEDM because of the narrower gap length in dry-WEDM. 2) Since the short circuiting rate is high in dry-WEDM, the normal discharge frequency is one third of conventional WEDM.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"31 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2004-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116802534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Definitions for micro and nano-technology are introduced and discussed. Applications within micro-electronics are first described. Attention is then drawn to the utilisation of micro- technology in orthopaedic engineering, where micro- and nano-sized effects occur in surgery. The role of unconventional micro and precision machining and deposition methods is considered, especially in relation to the use of titanium alloy for implants. Micromotions that occur in implants following surgery are discussed. The paper concludes with a discussion on the use of the rapid prototyping technology, micro stereolithography, for repair of diseased bone scaffolds.
{"title":"Studies of Micro- and Nano-Technology in Orthopaedic Engineering","authors":"J. McGeough","doi":"10.2526/JSEME.38.89_13","DOIUrl":"https://doi.org/10.2526/JSEME.38.89_13","url":null,"abstract":"Definitions for micro and nano-technology are introduced and discussed. Applications within micro-electronics are first described. Attention is then drawn to the utilisation of micro- technology in orthopaedic engineering, where micro- and nano-sized effects occur in surgery. The role of unconventional micro and precision machining and deposition methods is considered, especially in relation to the use of titanium alloy for implants. Micromotions that occur in implants following surgery are discussed. The paper concludes with a discussion on the use of the rapid prototyping technology, micro stereolithography, for repair of diseased bone scaffolds.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"55 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2004-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114656781","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A. Okada, Y. Uno, Kohsuke Sato, Ken Hachinota, K. Uemura, P. Raharjo
A new surface finishing process for bio-titanium alloy products by wide-area electron beam (EB) irradiation is proposed. In the wide-area EB irradiation equipment, a high-energy-density EB can be irradiated without concentrating the beam. Therefore, a wide-area EB with a maximum diameter of 60mm can be used for instantaneously melting or evaporating a metal surface. Experimental results clarified that the surface roughness becomes smaller and the surface glossiness becomes higher with increasing energy density of the beam. Under an appropriate irradiation condition, the surface roughness of titanium alloy machined with an end mill could be decreased from 10Rz to less than 1mRz in 150 seconds. Moreover, the corrosion resistance and the repellency could be improved simultaneously. Therefore, the wide-area EB irradiation method may enable the highly efficient surface smoothing and surface modification of bio-titanium alloy.
{"title":"A New Surface Finishing Process for Bio-Titanium Alloy Products by Wide-Area Electron Beam Irradiation","authors":"A. Okada, Y. Uno, Kohsuke Sato, Ken Hachinota, K. Uemura, P. Raharjo","doi":"10.2526/JSEME.38.89_27","DOIUrl":"https://doi.org/10.2526/JSEME.38.89_27","url":null,"abstract":"A new surface finishing process for bio-titanium alloy products by wide-area electron beam (EB) irradiation is proposed. In the wide-area EB irradiation equipment, a high-energy-density EB can be irradiated without concentrating the beam. Therefore, a wide-area EB with a maximum diameter of 60mm can be used for instantaneously melting or evaporating a metal surface. Experimental results clarified that the surface roughness becomes smaller and the surface glossiness becomes higher with increasing energy density of the beam. Under an appropriate irradiation condition, the surface roughness of titanium alloy machined with an end mill could be decreased from 10Rz to less than 1mRz in 150 seconds. Moreover, the corrosion resistance and the repellency could be improved simultaneously. Therefore, the wide-area EB irradiation method may enable the highly efficient surface smoothing and surface modification of bio-titanium alloy.","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"45 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2004-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116331196","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"High Precision EDM of Micro Shapes","authors":"Michikazu Uchida, Hideto Tanaka, S. Kawai","doi":"10.2526/JSEME.38.88_36","DOIUrl":"https://doi.org/10.2526/JSEME.38.88_36","url":null,"abstract":"","PeriodicalId":269071,"journal":{"name":"Journal of the Japan Society of Electrical-machining Engineers","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2004-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121067372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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