This thesis talk about practical application of wire electrical discharge machining (WEDM), which belongs to electro-erosion machining methods. This thesis is focused on the production of cutting dies produced by company FOR MIX s.r.o. Trenčín. We can consider the cutting die as a typical product of company´s product program. In the practical part of this diploma thesis, there is detail of technological aspects and operating costs for wire electrical discharge machining technology in specific condition of company FOR MIX s.r.o.

The presented diploma thesis deals with the issue of wire electrical discharge machining of SiSiC ceramics. The first part explains the principles of electrical discharge machining, describes the WEDM technology and presents the properties of the advanced ceramics. The second part consists of a detailed analysis of the cutting process of eighteen samples obtained with systematically changing process parameters. Based on the obtained results from EDX analysis, SEM electron microscopy and topography there was performed an analysis of the influence of process parameters on the cutting speed, surface roughness, kerf width and number of wire breaks with usage of the selected brass cutting wire. From the evaluated results it was possible to select a combination of parameters that ensured a stable machining process.

The aim of this dissertation are future trends of electrical discharge machining in conditions of a small tool factory. In the introduction is presented the theory of non-conventional machining. The practical part is focused on valuation the current level of electrical discharge machining, the importance of the use in a tool Nástrojárna Ryšavý. It also compares the level of leading global manufacturers of electrical discharge machines and future trends of electro-discharge technology.

Wire electrical discharge machining (WEDM) is a precision machining process that uses electrical discharges struck between an axially moving wire electrode and the workpiece to remove material through melting and vaporization. WEDM is replacing traditional processes like broaching for machining safety-critical components such as the turbine disk in the manufacture of fuel-efficient jet engines. The main issue preventing the more widespread use of WEDM is that due to WEDM being less productive than broaching, it currently requires 6 WEDM machine tools to replace a single broaching machine to maintain the same throughput. The main factor limiting WEDM productivity is wire breakage. To increase the Cutting Rate (CR) more power is required, and increasing power also increases the likelihood of breakage. The goal of this research is to determine whether wires thicker than the conventional 0.25 mm diameter will both optimize the cutting rate and minimize breakage. Thicker wires will allow for an increase in the duty factor, with a significantly decreased incidence of wire breakage. Given that an increased wire diameter also increases the kerf width, this research seeks to identify the optimal wire diameter that maximizes the linear cutting rate. This research concluded that using wire of optimal diameter in WEDM increases the CR by as much as 400%. / Thesis / Master of Science in Mechanical Engineering (MSME) / In order to secure jet engine blades onto the engine, complex features called Firtree Root Forms (FTRF) are used. These features need to be very precisely cut in order for the engine to work at peak efficiency. Currently, industry is using a manufacturing process called broaching to machine these FTRFs, however broaches wear out over time, which causes imprecise cuts. The solution to this is to use Wire Electrical Discharge Machining (WEDM). The problem with WEDM is that it takes on average 6 machines to replace a single broaching machine in terms of productivity. The objective of this project is to increase the cutting speed (and thus productivity) of WEDM, and one of the ways to do that is to increase the electrode wire diameter. This allows for more power to be used in the machining process without the risk of wire breakage, which is a major problem when cutting with WEDM. The research presented in this thesis successfully demonstrates that using thicker wires in WEDM can cut as much as 400% faster than the wires currently in common use in industry.

Wire Electrical Discharge Machining (WEDM) is a nontraditional machining process used for machining intricate shapes in high strength and temperature resistive (HSTR) materials. WEDM provides high accuracy, repeatability, and a better surface finish; however the tradeoff is a very slow machining rate. Due to the slow machining rate in WEDM, machining tasks take many hours depending on the complexity of the job. Because of this, users of WEDM try to predict machining rate beforehand so that input parameter values can be pre-programmed to achieve automated machining. However, partial success with traditional methodologies such as thermal modeling, artificial neural networks, mathematical, statistical, and empirical models left this problem still open for further research and exploration of alternative methods. Also, earlier efforts in applying the decision tree rule induction algorithms for predicting the machining rate in WEDM had limitations such as use of coarse grained method of discretizing the target and exploration of only C4.5 as the learning algorithm. The goal of this dissertation was to address the limitations reported in literature in using decision tree rule induction algorithms for WEDM. In this study, the three decision tree inductive algorithms C5.0, CART and CHAID have been applied for predicting material removal rate when the target was discretized into varied number of classes (two, three, four, and five classes) by three discretization methods. There were a total of 36 distinct combinations when learning algorithms, discretization methods, and number of classes in the target are combined. All of these 36 models have been developed and evaluated based on the prediction accuracy. From this research, a total of 21 models found to be suitable for WEDM that have prediction accuracy ranging from 71.43% through 100%. The models indentified in the current study not only achieved better prediction accuracy compared to previous studies, but also allows the users to have much better control over WEDM than what was previously possible. Application of inductive learning and development of suitable predictive models for WEDM by incorporating varied number of classes in the target, different learning algorithms, and different discretization methods have been the major contribution of this research.

This diploma thesis deals with the issue of electroerosion machining of materials used in the aerospace industry. The introductory part presents the layout of aerospace materials and the methods by which they can be machined. The next chapter describes the basic principles of EDM. The experimental part is focused on electroerosive cutting of NIMONIC 263 alloy. The greatest emphasis was placed on determining the influence of the cutting wire material on the rate of contamination of the surface layer of the workpiece. The quality of the machined surface was assessed depending on the used wire and the selected machining parameters.

This work deals with analysis of EDM wire cutting technology and aims to assess the current situation and the real possibilities of EDM wire cutting usage in a small engineering company. Furthermore, it addresses manufacturing technology of a model component and the subsequent economic evaluation.

This marter’s thesis deals with the technology of electrical discharge wire cutting. There is described the basic nature of the electrical erosion, EDM principle and WEDM principle. The main part deals with the application of wire cutting in the manufacture pulley 68-8M-130 with a description of technology on the wire cutter Excetek V 650. At the end of the work is devoted to the statistical evaluation of the precision machined surfaces.

The dissertation is focused on streamlining production on wire electric discharge machine during cutting metal alloys, specifically low-alloy steel quality by CSN 41 4220. The first part contains a study of the current and modern technologies EDM wire cutting. The second part is focused on identifying key parameters to influence the WEDM process, a detailed analysis of the machined surfaces of samples and wire electrodes used for cutting. The result of this work was to explore the possibility, whether by performing planned experiment and subsequent evaluation in the future to determine exactly setting the key parameters influencing the process of WEDM.

My thesis is aimed at the application of wire electical discharge machining technology in the production of woodworking tools. All of this in the conditions of Vydona company. There is a theory of machining method plus a well-aranged division of cutter tools for wood in the introduction. The practical part describes in detail the procedur of cutting shaped plate out of tungsten carbide. As a result of the technical and at the same time the economic evaluation is an establishment of hourly rate for machine.