Search

In order to achieve a mirror-like workpiece surface by EDM, a micro-energy EDM or a manual lapping is normally used. However, both methods are time consuming and economically unattractive. To have better performance, a sinking EDM machine was first used in this research on SKD 61 for a micro-energy discharge process followed by the electrophoretic deposition (EPD) process to coat Al2O3 particles uniformly on a rotation electrode. The precision polishing process was then applied on the discharged workpiece with suitable parameters including the voltage, electrode rotating speed, pH value of electrolyte, and abrasive concentration. After the EDM process, the surface roughness and the recast layer thickness of a workpiece could also be reduced. The experimental data showed that when 0.3 μm of Al2O3 particles was used for the EPD polishing process, the initial roughness of a discharge surface could be improved from 0.52 μm Ra (6.50 μm Rt) to a mirror-like surface of 0.068 μm Ra (0.742 μm Rt). Also, the total working time could be reduced significantly to within the range of 5 to 10 min. [ABSTRACT FROM AUTHOR]

This paper presents a residual modified grey dynamic model RGM(1,3) in order to fit and predict the performance characteristics of an electro-conductive ceramic (Al2O3+30%TiC) during electrical discharge machining (EDM). Grey system theory is suitable for the system in which some information is poor, incomplete and uncertain, so it is feasible to study the performance characteristics of EDM with this model. The RGM(1,3) model is modified to promote the forecasting accuracy of predicting values using the residual grey dynamic model GM(1,1). The fitted and predicted values of various performance characteristics, including the material removal rate (MRR), maximum surface roughness (Rmax), and electrode wear ratio (EWR) agreed sufficiently with the experimental data. It is proved that RGM(1,3) model fitted and predicted the above performance characteristics with a high predicting accuracy. Therefore this procedure of grey forecasting model is relatively simple and convenient, and it is greatly suited for the analysis of question which obtained a few experimental data, and acts an auxiliary to calculate the unfinished experimental data. [ABSTRACT FROM AUTHOR]