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 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.

This master´s thesis focuses on the basic principles of the nonconventional technology of electrical discharge machining (EDM) with an emphasis on wire-cut electrical discharge machining performed in a mediumsized company. The thesis deals with manufacture of a belt pulley 75-8M-130, and checks of accuracy of wire-cut EDM machines. Following the study of the current status of electrical discharge machining in the engineering company, measures for assurance and increase of accuracy of wire-cut EDM machines are proposed.

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.

This master´s thesis deals with unconventional technology of wire electrical discharge machining. There are described the principles and essence of electrical discharge machining and the principles related to wire electrical discharge machining with emphasis on the application of this technology in terms of medium-sized engineering company. There is also described the complete assembly of technolgy wire cutting and machining on wire cutter Excetek V 650. Then in the work there are statistically evaluated parameters precision machined surfaces, specifically to the belt pulley 116-8M-130. At the end of the work there is the technical-economic evaluation that addresses the hourly cost of machining on wire cutter Excetek V 650.

This dissertation deals with research on the numerical modelling of electrical discharges in laboratory long air gaps excited with positive switching impulses. It begins with the preliminary work of several scientists during the last decades, making a detailed analysis of different approaches for modelling all the stages in a full discharge. The relations between these models are identified as well as the effect on the outcome when modifying some important input parameters. The general concept describing the discharge phenomenon usually includes three main elements: the streamer inception, the streamer-to-leader transition and the stable leader propagation. These elements are present in many of the analysed models and the main differences between them are the assumptions and simplifications made by each author at a specific point in their methodologies. The models are usually simplified by assigning experimentally determined values to physical constants pertinent to different stages of the full discharge. These constants are the potential gradient in the leader-corona region to sustain the leader propagation, the charge per unit length along the leader channel which depends on the atmospheric conditions and the voltage impulse wave shape; and the leader propagation velocity, which is closely related to the discharge current. The dissertation includes the results of laboratory work related the study of leaders in long gap discharges, electrical parameters and optical records. By reconstructing the three-dimensional leader propagation for the rod-to-plane configuration, it was possible to study the random tortuous path followed by the leader as it propagates. One important element included in the discharge modelling is the representation of the leader-corona region in front of the leader tip as it propagates towards the grounded electrode. For the calculation of the net charge available in the leader-corona region, two new methodologies were pro-posed based on the electrostatic potential distribution obtained from a finite element method solver. This allowed the inclusion of more elements representing different parts of the discharge in the simulation domain. In the final part, all the analysed elements and the new proposed ones were included in a new methodology for the modelling of electrical dis-charges in long air laboratory gaps. The results obtained from this methodology were compared to experimental data. A good agreement was found between the simulation results and the experimental data.

This paper aims to create a hard modification layer of WC/Co/Fe on the surface of SKD11 work steel by using a new closed-type method of surface electrical discharge coating with the self-made tool electrode and CNC electrical discharge machine. The tool electrode is the composition of a semi-sintered powder compacted electrode and a cooper rod. The sintered powder compacted electrode making process is first to mix the WC/Co and Fe powders uniformly at 8:1, 4:1, 2:1 and 1:1 in weight ratio. Continually, it will form the cylinder of 8mm in diameter and 18mm in length approximately by compacting in different pressure (50~200 MPa) and sintering temperature (300~900 ¢J). The EDM condition is 1~12A discharge current, 25~500£gs pulse time, and 50% duty factor. The electrical discharge machining is proceeding in kerosene with tool electrode as cathode and workpiece as anode. The result is as following. It can be concluded that the best condition to fabricate the sintered powder compacted electrode is 1:1 in weight ratio between WC/Co and Fe powders; with 200Mpa compacting pressure and sintering temperature at 900¢J, which results in lowest electrical resistivity. Under such condition, the area covered ratio can reach 100% at best EDM condition, which is pulse time £non = 50 £gs, rest time £noff = 50 £gs, 8A in current and 1.5 min in machining time. The surface hardness of workpiece increases with machining time. The surface hardness dramatically increases to Hv1500 as machining time over 1.5 min. The hardness of modification layer equals to the WC/Co particle itself which brings to the best wear ability. Moreover, the hardness of under surface in between 48 £gm is much higher than it of the SKD11 work steel. The hardness in between 30 £gm can reach up to Hv1200 in particular. The hardness of surface modification layer increases linearly with machining time. However, the limit of surface modification layer is about 30 £gm, and the needed time is below 5 min.

Η εργασία ξεκινά με την θεμελίωση βασικών εννοιών των εκκενώσεων και στη συνέχεια παρατίθενται οι κυριότερες ηλεκτρικές εκκενώσεις σε αέριο διάκενο. Ακολουθεί μια ιστορική αναδρομή του ηλεκτρικού ανέμου και μια εκτενής βιβλιογραφία πάνω στο θέμα αυτό καθώς και πρόσφατες εργασίες. Το θέμα της διπλωματικής εργασίας ήταν να παρουσιάσει μια δισδιάστατη μελέτη των ηλεκτρικών εκκενώσεων σε διάκενα με την χρήση υδροδυναμικών εξισώσεων, δίνοντας έμφαση α)στην δισδιάστατη εξομοίωση της «γένεσης» του streamer (κύμα ιονισμού) και της διάδοσής του σε διάκενο και β)την εξομοίωση του ηλεκτρικού ανέμου. Αναπτύχθηκαν δυο μοντέλα, ένα για τον streamer (μοντέλο Α) και ένα για τον ηλεκτρικό άνεμο (μοντέλο Β). Παρατίθενται αποτελέσματα και συμπεράσματα πάνω στα χαρακτηριστικά του streamer (ταχύτητα, πεδίο κεφαλής, … ) και του ηλεκτρικού ανέμου (ταχύτητα) σε σχέση με πειραματικά και θεωρητικά αποτελέσματα. Στο μοντέλο Α έγιναν εξομοιώσεις για διαφορετικές αρχικές συνθήκες και οι τιμές της ταχύτητας διάδοσης του streamer που προέκυψαν συμφωνούν με την βιβλιογραφία. Με κάποιες παραδοχές οι οποίες απλοποιούν την μελέτη του ανέμου και δεν παρεκκλίνουν από την φυσική του φαινομένου καταφέραμε να αναπτύξουμε το μοντέλο Β υπολογίζοντας την ταχύτητά του που συμφωνεί με την βιβλιογραφία. Αξίζει να αναφερθεί ότι η διπλωματική εργασία ανέδειξε τις δυνατότητες και αλλά και τις αδυναμίες του FlexPDE στην επίλυση δύσκολων διαφορικών εξισώσεων. / -

A plasma arc erosion process can be used to create metal and metal oxide particles in the ultra-fine size range (<70 µm). An electric arc is struck between two metallic electrodes, submerged in water, melting the surface of the electrodes. When the arc collapses a high energy pressure wave strikes the molten surface of the electrode. When the pressure wave strikes the molten metal, small metallic particles are created from the molten metal and are immediately cooled in the water. Previous research developed a process that used a constant current power supply and electrode motion to create ultra-fine particles. This research improves upon previous research by using a pulsed power supply similar to those used in Electrical Discharge Machining (EDM). The pulsed power supply eliminates the need for electrode motion and improves the rate of particle production, provides control over size of the particles created, and reduces the amount of energy needed to produce the particles. The new process improves the maximum particle production rate from 3.6 g/hr to 14 g/hr, provides a method to control the mean diameter of the particles produced, and reduces the amount of energy needed from 200 kWh/kg(previous constant current process) to 10.6 kWh/kg(using the pulsed power supply).

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.