Wire Electro-Discharge Machining of Advanced Engineering Materials

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Title: Wire Electro-Discharge Machining of Advanced Engineering Materials
Author: Miller, Scott Franklin
Advisors: Dr. Ron Scattergood, Committee Member
Dr. Albert Shih, Committee Chair
Dr. John Strenkowski, Committee Member
Abstract: The goal of this research was to create models and guidelines for Wire Electrical Discharge Machining (WEDM) of new advanced engineering materials and for truing of metal bond diamond grinding wheels. The development of new advanced engineering materials and the need to meet demand for precise and flexible prototype and low-volume production of components has made WEDM an important manufacturing process. One goal of this research is to investigate the effect of spark on-time duration and spark on-time ratio, two critical WEDM process parameters, on truing of metal bond diamond grinding wheels and machining of three types of new advanced engineering materials; porous metal foams, sintered Nd-Fe-B magnets, and carbon-carbon composite fuel cell bipolar plates. An envelope of feasible process parameters for material removal rate is developed for each material, according to machine, tooling, and physical limitations. This envelope is then applied to cut sections of carbon-carbon bipolar plate and sintered Nd-Fe-B magnet to minimum thickness. Effect of process parameters on limit of thickness of the sintered Nd-Fe-B magnet is discussed. The surfaces machined by WEDM were qualitatively studied using Scanning Electron Microscopy to observe surface features and characteristics. Experiments were conducted to measure temperatures generated during the EDM process using infrared spectrometry on three different materials; 1. metal bond diamond grinding wheel, 2. WC-Co, and 3. copper.
Date: 2003-04-09
Degree: MS
Discipline: Mechanical Engineering
URI: http://www.lib.ncsu.edu/resolver/1840.16/883


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