Electrical discharge machining (EDM) is perhaps the most prevalent non-traditional machining process in industry. Therefore, a great amount of effort has been invested towards improving the process. One result of these efforts was the introduction of CNC capabilities to EDM machine tools. Though CNC capabilities are predominantly used for performing orbital EDM, they may also be used for electrical discharge (ED) milling. Cylindrical tools are typically used in ED milling. While other tooling concepts have been developed for use with CNC EDM, this area of EDM is lacking in research. In this work an oblong set of tools for ED milling is presented. The set contains tools capable of machining cavities with both round and sharp features. Motivation for development of the tool set is discussed along with the benefits accompanied by the use of these tools. The cavity profiles considered in this work are divided into three groups based on concavity, continuity and geometric composition. Based on these groups, algorithms are presented for tool type selection and tool size calculation. Tool path planning strategies for each of the tool types are also presented. Two examples are presented in which the algorithms are applied to 2D profiles. The first of these profiles is star shaped, while the second is gear shaped. Both examples were machined on a 4-axis CNC EDM using the oblong tools presented in this work. When compared to equivalent cylindrical/square tools, the oblong tools used for the machining of the cavities provided a substantial increase in frontal area corresponding to improved material removal rates. Furthermore, for both examples, the complete machining of a single layer is accomplished with only one pass of the tool. / Thesis / Master of Applied Science (MASc)

Submitted by Edineia Teixeira (edineia.teixeira@unioeste.br) on 2017-08-24T19:35:51Z No. of bitstreams: 2 Daniele _Ficanha2016.pdf: 2114781 bytes, checksum: 4cf98bf8089cd41a33e68e5cfc4c1ba8 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Made available in DSpace on 2017-08-24T19:35:51Z (GMT). No. of bitstreams: 2 Daniele _Ficanha2016.pdf: 2114781 bytes, checksum: 4cf98bf8089cd41a33e68e5cfc4c1ba8 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) Previous issue date: 2016-07-11 / The function of metal silos consists in storing and preserving the quality of the grains. For that, it is extremely important the correct dimensioning in order to guarantee efficiency and security of the set. The possibility of a metal silo implantation is based mainly in the cost and weight of the primary raw material, the steel. The side plates represent the biggest part of the raw material used. The feasibility of a new fixation element, the alternative bolt, responsible for the connections of the silo body’s elements increase the resistance of the side plate, becoming attractive and economic for all users of metal silos. The elaboration of an alternative bolt was based on ISO 4016 (2000) regarding chemical composition and mechanical properties. Mass from the hexagonal head of the traditional bolt was withdrawn and added in the cut plan of the alternative bolt, making it an oblong element and round head. Prototypes of the alternative bolt were developed with the same raw material, temper process and bichromatization as the executed in the traditional bolts. Twenty-three samples of the traditional bolt and sixteen samples of the alternative bolt were produced through the method of direct shearing. The model’s premises were verified, in which the increase in shearing area in the alternative bolt’s cutting plan produced effects in the shearing resistance in the traditional bolt. Through the result of the alternative bolt, it was possible to determine the random error average variable of the model , validating the theoretical functions of the probability distribution for the representation of the statistic information of this random variable, determining the correct strength of the alternative bolt as 107,40 kN. In order to use the alternative bolt in metal silos, 27 samples of the traditional bolt and 3 samples of the alternative bolt were compared, both using support plates of the same material used in the silos, to verify if the plate influences the bolt’s shearing resistance. The parameters used in the definition of the crushing and tearing resistance were determined by tensile tests on the support plates, quantification to the breaking point, as well as the distance between the hole and the edge were determined, to be superior to the resistance of the bolts calculations. It was not possible to determine the influence of the support plate in the resistance of the alternative bolt shear, since the support plate crushed it and it reached only deformed plastic state. The comparison between the averages for the sample of the alternative bolt may have produced positive effects in the shear bolt resistance. / A função dos silos metálicos consiste em armazenar e preservar a qualidade dos grãos. Para isso, é de suma importância o dimensionamento adequado, a fim de garantir a eficiência e a segurança do conjunto. A possibilidade de implantação de um silo metálico baseia-se principalmente no custo e no peso da matéria prima: o aço. As chapas laterais representam a maior parte da matéria prima utilizada. A viabilização de um novo elemento de fixação, o parafuso alternativo, responsável pelas ligações dos elementos do corpo do silo aumentam a resistência da chapa lateral, tornando-se atrativo e econômico para todas as fontes usufruintes dos silos metálicos. A elaboração do parafuso alternativo baseou-se na ISO 4016 (2000) quanto à composição química e às propriedades mecânicas. Retirou-se massa da cabeça sextavada do parafuso tradicional e adicionou-se no plano de corte do parafuso alternativo, formando um elemento oblongo de cabeça redonda. Confeccionaram-se protótipos do parafuso alternativo com a mesma matéria prima, processo de têmpera e bicromatização que a executada nos parafusos tradicionais. Ensaiaram-se 23 amostras do parafuso tradicional e 16 amostras do parafuso alternativo pelo método do cisalhamento direto. Foram verificadas as suposições do modelo, no qual o aumento da área de cisalhamento no plano de corte do parafuso alternativo produziu efeitos na resistência ao cisalhamento do parafuso tradicional. A partir do resultado do parafuso alternativo foi possível determinar a média da variável aleatória erro do modelo, validando as funções teóricas de distribuição de probabilidades para a representação da informação estatística dessa variável aleatória, determinando a força correta do parafuso alternativo, de 107,40 kN. Com o intuito de utilizar o parafuso alternativo nas chapas do corpo de silos metálicos, comparou-se através do ensaio de 27 amostras do parafuso tradicional e 3 amostras do parafuso alternativo, ambos utilizando chapas laterais de silos metálicos para verificar se há influência da mesma na resistência ao cisalhamento dos parafusos. Os parâmetros utilizados na definição da resistência ao esmagamento e rasgamento foram determinados a partir do ensaio de tração das chapas de apoio, quantificação da tensão de ruptura, tal que as distâncias entre furo e borda foram determinadas para serem superiores à resistência de cálculo dos parafusos. Não foi possível a determinação da influência da chapa de apoio na resistência ao cisalhamento do parafuso alternativo, visto que a chapa de apoio esmagou e o mesmo chegou apenas ao estado de deformação plástica. A comparação entre as médias para a amostra de parafuso alternativo produziu efeitos positivos na resistência ao cisalhamento dos parafusos