Guangdong Province Key Laboratory of Digital Manufacturing Equipment

Dongguan, China

Guangdong Province Key Laboratory of Digital Manufacturing Equipment

Dongguan, China
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Ming W.,Zhengzhou University of Light Industry | Zhang Z.,Huazhong University of Science and Technology | Zhang Z.,Guangdong Province Key Laboratory of Digital Manufacturing Equipment | Zhang G.,Huazhong University of Science and Technology | And 7 more authors.
Materials and Manufacturing Processes | Year: 2014

In this paper, an experimental plan for Taguchi method of experimental design of processing tungsten steel YG15 has been conducted according to Gaussian process regression (GPR) with combinatorial kernel functions. The aim is to develop a proper nonlinear model and seek optimal parameters on materials removal rate (MRR) and 3D surface quality (Sz and Sq) by integrated GPR and non-dominated sorting genetic algorithm-II (NSGA-II). By this method, it has been demonstrated that the method of integrated GPR and NSGA-II is an effective way for multi-objective optimization on 3D micron-scale surface topography in wire electrical discharge machine (WEDM). © 2014 Taylor & Francis Group, LLC.


Ming W.,Zhengzhou University of Light Industry | Zhang G.,Huazhong University of Science and Technology | Li H.,Huazhong University of Science and Technology | Li H.,Guangdong Province Key Laboratory of Digital Manufacturing Equipment | And 4 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2014

This paper proposed a hybrid intelligent process model, based on finite-element method (FEM) and Gaussian process regression (GPR), for electrical discharge machining (EDM) process. A model of single-spark EDM process has been constructed based on FEM method, considering the latent heat, variable heat distribution coefficient of cathode (fc), and plasma flushing efficiency (PFE), to predict material removal rate (MRR) and surface roughness (Ra). This model was validated using reported analytical and experimental results. Then, a GPR model was proposed to establish relationship between input process parameters (pulse current, pulse duration, and discharge voltage) and the process responses (MRR and Ra) for EDM process. The GPR model was trained, tested, and tuned using the data generated from the numerical simulations. Through the GPR model, it was found that responses of EDM process can be accurately predicted for the chosen process conditions. Therefore, for the selection of optimum parameters, the hybrid intelligent model proposed in this paper can be used in EDM process. © 2014, Springer-Verlag London.


Zhang G.,Huazhong University of Science and Technology | Li H.,Huazhong University of Science and Technology | Zhang Z.,Northwestern Polytechnical University | Ming W.,Huazhong University of Science and Technology | And 2 more authors.
Machining Science and Technology | Year: 2016

During the wire electrical discharge machining (WEDM) process, the vibrations of the wire generated by the gap force is the main cause of imprecision. To achieve more precise results with better accuracy, understanding of the vibration management of the wire is essential. In this article, the wire’s vibration behavior is introduced briefly, followed by an exploration of an equation, derived from Hamilton’s principle, which expresses the vibration of a wire moving axially. This equation is presented under some simplified assumptions. In addition, the relationship between the maximum amplitude of the vibration and the main relative variables is presented. The solution demonstrates that a thicker workpiece results in a larger amplitude of vibration, yet the axial speed of the wire has no impact on the maximum amplitude. © 2016, © Taylor & Francis Group, LLC.


Zhang G.,Huazhong University of Science and Technology | Chen Z.,Huazhong University of Science and Technology | Zhang Z.,Huazhong University of Science and Technology | Huang Y.,Huazhong University of Science and Technology | And 3 more authors.
International Journal of Machine Tools and Manufacture | Year: 2014

In medium-speed wire electrical discharge machining (MS-WEDM), wire in the area near the guide wheel and between the two guide wheels obviously form the wire bending deformation due to wire tension, electrostatic force, electrodynamics force, hydrodynamic force, temperature increment, etc. Besides, the wire deflection would have a direct influence on the machining accuracy, productivity and stability. In this paper, first of all, main causes of wire electrode deformation are proposed to better understand its fundamental mechanism. Second, two macroscopic mechanical models of wire deflection are developed in the area near the guide wheel and between the two guide wheels considering temperature increment and wire vibration in machining 20 mm-thickness workpiece process, respectively. Moreover, the numerical solution of deflection in the area near the guide wheel and the theoretical solution of deflection between the two guide wheels has been worked out. Then, the analysis of the variation trend of wire deflection and the influences of wire deflection on the machining process have been conducted. Eventually, from the confirmation experiment and comparison with other researchers' models, it has been proved that the macroscopic mechanical models of wire deflection in MS-WEDM process are reasonable and reliable. In addition, according to macroscopic mechanical models, some of the practical approaches of reducing wire deflection have been proposed to improve machining accuracy, and these high-precision models can be applied into NC system to set a compensation for wire deflection in the future. © 2014 Elsevier Ltd.


Chen Z.,Huazhong University of Science and Technology | Huang Y.,Huazhong University of Science and Technology | Huang Y.,Guangdong Province Key Laboratory of Digital Manufacturing Equipment | Huang H.,Huazhong University of Science and Technology | And 3 more authors.
International Journal of Machine Tools and Manufacture | Year: 2015

Abstract In this paper, a three-dimensional multi-physics coupling model (thermal model, electromagnetic field model and structural model) is proposed for analyzing and controlling the vibration of wire electrode in cutting thin plate process. Firstly, a three-dimensional thermal model is developed to evaluate temperature distribution of wire electrode considering heat convection and heat conduction, and the numerical solutions of wire temperature increment are performed under different process parameters. Secondly, the mechanism of electromagnetic force acting on wire tool is clarified in detail, and a spacial finite element method (FEM) program is designed to analyze the electromagnetic field considering electromagnetic induction. Then, combining thermal model with electromagnetic field model, and conventional structural model, a multi-physics coupling model is established to acquire the frequency and amplitude of wire vibration under random multiple-spark discharges. Furthermore, the simulational results of multi-physics coupling model on wire vibration show a good agreement with experimental data, and the influencing rules of processing parameters on wire vibration are also illustrated to seek the best parameter combination. Eventually, three practical methods are presented to restrain wire vibration performance, and the significant effects on suppressing the wire vibration and improving geometric accuracy have been obtained. © 2015 Elsevier Ltd. All rights reserved.


Huang Y.,Huazhong University of Science and Technology | Ming W.,Huazhong University of Science and Technology | Guo J.,Huazhong University of Science and Technology | Zhang Z.,Huazhong University of Science and Technology | And 4 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2013

In this paper, the effects and the optimization of cutting parameters on surface roughness (Ra) and material removal rate (MRR) in the wire electrical discharge machining (WEDM) of high hardness tool steel YG15 are analyzed. In the WEDM process, the key process parameters, such as pulse-on time, pulse-off time, power, cutting feed rate, wire tension, wire speed, and water pressure, are optimized. Experimental data were initially collected based on the Taguchi method of experimental design, which are L18 (21× 35) and L18 (21× 34) Taguchi standard orthogonal array on rough and finish cutting experiments, respectively. The level of importance of the cutting parameters on the Ra and MRR was determined on both finish and rough cutting by using statistical analyses; average gap voltage is discussed in order to balance cutting efficiency and stability on both finish and rough cutting. In addition, comparative analysis of finish and rough cutting is drawn to analyze the difference between rough cutting and finish cutting. Then, regression models and signal-to-noise ratio are used to obtain the optimum cutting parameter combination. Finally, the results present the optimized MRR and Ra of the rough and finish process, respectively, and confirm the efficiency and abilities of the model. © 2013 The Author(s).


Chen Z.,Huazhong University of Science and Technology | Zhang Z.,Huazhong University of Science and Technology | Ming W.Y.,Guangdong Province Key Laboratory of Digital Manufacturing Equipment | Huang H.,Huazhong University of Science and Technology
Advanced Materials Research | Year: 2014

Wire electrical discharge machining (WEDM) is extensively used in the mold, instrument and manufacturing industries, and rough cutting operation in WEDM is treated as a challenging process because improvement of more than one machining performance measures viz. metal removal rate (MRR), roughness (Ra) are sought to obtain a precision work. In this paper, first of all, a set of Taguchi experiment (L18 21×34) is carried out based on the Taguchi method. Secondly, two groups of ANOM are completed to obtain the influence trends of each parameters on material removal rate (MRR) and roughness (Ra), respectively. Eventually, three groups of best process parameters combination are acquired to meet high material removal rate (MRR) and low roughness (Ra) simultaneously, it can provide guiding significance to actual machining process. © (2014) Trans Tech Publications, Switzerland.


Li H.,Huazhong University of Science and Technology | Guo J.W.,Huazhong University of Science and Technology | Ming W.Y.,Huazhong University of Science and Technology | Zhang Z.,Guangdong Province Key Laboratory of Digital Manufacturing Equipment
Advanced Materials Research | Year: 2014

Nano electrical discharge machining (nano-EDM) method is an attractive measure to the manufacturing of parts of nanoscale dimension or precision, and is getting more and more interest of researchers, however, due to the incompleteness of EDM theories, the development of more advanced nano-EDM technology is impeded. In this paper, a hybrid simulation model, namely, combination of the molecular dynamics simulation model and two-temperature model of single discharge process in nano-EDM is constructed to study the machining process of nano-EDM from the thermal point of view. © (2014) Trans Tech Publications, Switzerland.


Zhang G.,Huazhong University of Science and Technology | Zhang Z.,Huazhong University of Science and Technology | Guo J.,Huazhong University of Science and Technology | Ming W.,Huazhong University of Science and Technology | And 3 more authors.
Materials and Manufacturing Processes | Year: 2013

This study analyzed the workpiece surface quality (Ra) and the material removal rate (MRR) on process parameters during machining SKD11 by medium-speed wire electrical discharge machining (MS-WEDM). An experimental plan for composite design (CCD) has been conducted according to methods response surface methodology (RSM) and subsequently to seek the optimal parameters. The experimental data were utilized to model MRR and Ra under optimal parameter condition by a backpropagation neural network combined with genetic algorithm (BPNN-GA) method. Eventually, the comparisons between the results from BPNN-GA and those from the RSM demonstrate that BPNN-GA method is a more effective way for optimizing MS-WEDM process parameters. © 2013 Copyright Taylor and Francis Group, LLC.


Chen Z.,Huazhong University of Science and Technology | Huang Y.,Huazhong University of Science and Technology | Zhang Z.,Huazhong University of Science and Technology | Li H.,Huazhong University of Science and Technology | And 3 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2014

Wire electrical discharge machining (WEDM) has occupied an important position in some high-precision and high-performance manufacturing industries due to its capability of accurate and efficient machining parts with varying hardness or complex shapes. However, the high-machining precision and efficiency, especially at rough corner cutting, cannot be satisfied simultaneously because of some phenomena such as wire rupture, deflection, vibration, etc. This paper aims to analyze and reduce the geometrical inaccuracy of rough corner cutting; first of all, the major causes of corner inaccuracy (45°, 90°, and 135° angle) are analyzed in detail. Secondly, an elliptic fitting method is proposed to describe the trajectory of wire electrode center, and the feasibility of model is confirmed by measuring the corner edge of workpiece. Moreover, three sets of Taguchi experiments (L2737) are designed to investigate the main effect and influence trends of control factors on corner error. Eventually, some optimized control factor combinations are sought by generalized non-linear regression model. As a result of confirmatory experiments, more than 50 % decrease of corner error has been achieved at 5 mm/min cutting feedrate (a high-cutting feedrate of the machine tool used in this study) by the optimized control factors combination in rough corner cutting. © 2014, Springer-Verlag London.

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