The adoption of Electrical Discharge Machining (EDM) technologies to mainstream manufacturing saw dramatic advances in the process starting in the 1980's. Wire Electrical Discharge Machining (WEDM) in particular achieved enhancements in cutting speed of over 800% between 1980 and 1992 due to improvements in generator and wire technology. Since then, increases in cutting speed have been gradual. To achieve dramatic improvements to the process once again, a paradigm shift, from improving upon existing technologies to introducing and developing new one is required. In this light, an investigation into the proof-to-concept and development of a novel hybrid machining process based upon Wire Electrical Discharge Machining (WEDM) and abrasive technologies is presented. In the process termed Abrasive Wire Electrical Discharge Machining (AWEDM), material removal is shown to occur by the simultaneous action of electrical erosion and abrasion. Through experimental evaluation, this combination is shown to bring about a manyfold improvement in the material removal rate and to generate machined surfaces with minimal recast layer, in comparison to conventional WEDM processes. To understand the operation of the process and to control the proportion of abrasion and EDM taking place, the effect of varying the process conditions is studied. The servo-reference voltage and peak discharge current, in particular, provide effective means to control the process. Practical implementation of the process presents several challenges, such as accurately guiding an abrasive wire; a discussion of some of these issues and possible solutions is included. The need for a wire that is specially suited to AWEDM is demonstrated with a discussion of the requirements and possible designs for such a wire. Whether or not a manufacturing process sees practical industrial use is chiefly dictated by economics. By considering the increase in both productivity and wire cost, AWEDM is shown to be economically feasible and offer potentially substantial benefits. This work ultimately serves as the basis for future work with respect to AWEDM. The work herein covers a broad range of topics in hopes of guiding future areas of research. / Thesis / Master of Applied Science (MASc)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/23146 |
| Date | 11 1900 |
| Creators | Menzies, Ian |
| Contributors | Koshy, Philip, Mechanical Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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