Optimization of Design and Manufacturing Processes for Wire-Electrochemical Spark Machining by using an Expert system

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Research areas:
Year:
2014
Type of Publication:
Article
Keywords:
ECSM, EDM, ECM, CIM, Wire-ECSM, KBS
Authors:
Morteza Sadegh Amalnik
Journal:
IJAIM
Volume:
3
Number:
2
Pages:
56-62
Month:
September
Abstract:
Electrochemical machining ECM and electro-discharge machining EDM are well established non-conventional manufacturing processes. In ECM the material is removed by electrolytic dissolution of the anodic work piece in the presence of electrolyte that fills the inter electrode gap. In EDM, the material is removed by the erosive action of discharges occurring across a dielectric fluid. Electrochemical spark machining ECSM is a machining process that combines ECM and EDM and removes material by the both ECM and EDM actions. In this paper Optimization of design and manufacturing processes for wire-electrochemical spark machining by using an expert system is developed. A knowledge base system for improving ECSM-wire machining based on object oriented techniques is introduced. The design description is obtained through a feature-based approach. Seven different classes of design features are interactively acquired. The attributes of steel as work piece material, copper wire-electrode as a tool material, one type of electrolyte solutions, and one size of Wire-Electro-Chemical Spark Machine (Wire-ECSM), machining conditions such as pulse-on time, off-time, and current and, nozzle distance are stored in a database. For each design feature, information needed in manufacturing, such as the machining cycle time and cost, material removal rate, width of cut, maximum possible feed rate, working feed rate, side clearance, cutting area, operation efficiency, are estimated. It can also be integrated within a CIM environment.
Full text: IJAIM_294_Final.pdf

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