MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT MECHNICAL ENGINEERING TECHNOLOGY A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS LECTURER: PHAM HUY TUAN, Assoc. STUDENT: VO TRAN MINH DINH SKL009920 Ho Chi Minh City, February 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS VO TRAN MINH DINH Student ID: 18144014 Major: MECHNICAL ENGINEERING TECHNOLOGY Advisor: PHAM HUY TUAN, Assoc. Ho Chi Minh City, February 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS VO TRAN MINH DINH Student ID: 18144014 Major: MECHNICAL ENGINEERING TECHNOLOGY Advisor: PHAM HUY TUAN, Assoc. Ho Chi Minh City, February 2023 Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education HCMC UNIVERSITY OF TECHNOLOGY THE SOCIALIST REPULIC OF AND EDUCATION VIETNAM FACULTY FOR HIGH-QUALITY Independence – Freedom – Happiness TRAINING CAPSTONE PROJECT ASSIGNMENT Advisor: PHAM HUY TUAN, Assoc.
Students ‘s name: VO TRAN MINH DINH Student ID: 18144014 1. Project title: A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS 2. Initial material provided by the advisor: − Die – sink EDM machine: Accutex DS – 430S CM − PZT actuator: P-225.10 PICA Power Piezo Actuator − Surface roughness tester: Mitutoyo SURFTEST SJ 201P − Ready – made Vibration – assisted Tool (inherited from the previous graduation thesis research) 3. Content of the project: − Study and research on principles and characteristics of Electrical discharge machining method − Research on vibration-assisted machining methods − Study structures and design principles of vibration - assisted tool integrated on the electrode holder of EDM machine − Manufacturing tool and executing the experiments then assess its efficiency 4.
Expected products: − Capstone report − Design drawings − Tool and results of the experiment 5. Date of assignment: 6. Date of submission: 7. Presentation language: The report: English Vietnamese Presentation: English Vietnamese DEAN HEAD OF DEPARTMENT ADVISOR (Sign with full name) (Sign with full name) (Sign with full name) Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education HCMC UNIVERSITY OF TECHNOLOGY THE SOCIALIST REPULIC OF AND EDUCATION VIETNAM FACULTY FOR HIGH-QUALITY Independence – Freedom – Happiness TRAINING CAPSTONE PROJECT EVALUATION FORM (FOR ADVISOR USE ONLY) Title of thesis: A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS Major: Mechanical Engineering Technology Committee Number Student’s name 01: Vo Tran Minh Dinh Student’s ID: 18144014 Advisor: Pham Huy Tuan Academic Position: Assoc.
Name of Institute: COMMENTS 1. COMMENTS ON ATTITUDE AND BEHAVIOR OF STUDENTS. COMMENTS ON RESULTS OF CAPSTONE PROJECT 2. Structure of the capstone project.
Results of capstone project. Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education. Capstone strengths and weaknesses. EVALUATION MAX ACHIEVED No.
CONTENT POINT POINT 1. Structure of the capstone project 30 Student follows exactly the format for capstone project given by FME 10 The motivation of the project is clearly provided in the thesis 10 The NEED of project is clearly shown in the thesis 10 2. Main contents (demonstration that students have ability to): 50 Apply knowledge of math, engineering, and science 5 Analyze and interpret data 10 Design and manufacturing the system, component or process to meet 15 needs Improvement and development in future 15 Use the software and technical tool to solve the problem 5 3. Real-life applications of capstone project 10 4.
Products of capstone project 10 Total 100 4. CONCLUSIONS Accept Reject Ho Chi Minh City, …. /2023 ADVISOR (Sign with full name) Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education HCMC UNIVERSITY OF TECHNOLOGY THE SOCIALIST REPULIC OF AND EDUCATION VIETNAM FACULTY FOR HIGH-QUALITY Independence – Freedom – Happiness TRAINING CAPSTONE PROJECT EVALUATION FORM (FOR REVIEWER USE ONLY) Title of thesis: A VIBRATION-ASSISTED EDM TOOL TO ENHANCE THE MANUFACTURING PROCESSS Major: Mechanical Engineering Technology Student’s name 01: Vo Tran Minh Dinh Student’s ID: 18144014 Committee No 03 Reviewer: Truong Quang Tri Academic Position: PhD Name of Institute: COMMENTS 1. COMMENTS ON ATTITUDE AND BEHAVIOR OF STUDENTS.
COMMENTS ON RESULTS OF CAPSTONE PROJECT 2. Structure of the capstone project. Results of capstone project. Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education.
Capstone strengths and weaknesses. EVALUATION MAX ACHIEVED No. CONTENT POINT POINT 1. Structure of the capstone project 30 Student follows exactly the format for capstone project given by FME 10 The motivation of the project is clearly provided in the thesis 10 The NEED of project is clearly shown in the thesis 10 2.
Main contents (demonstration that students have ability to): 50 Apply knowledge of math, engineering, and science 5 Analyze and interpret data 10 Design and manufacturing the system, component or process to meet 15 needs Improvement and development in future 15 Use the software and technical tool to solve the problem 5 3. Real-life applications of capstone project 10 4. Products of capstone project 10 Total 100 4. CONCLUSIONS Accept Reject Ho Chi Minh City, ….
/2023 REVIEWER (Sign with full name) Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education DISCLAIMER I certify that this graduation project is my own research that I implemented and studied on my own. The data and figures presented in the report were cited and referenced source annotations. They are all true and trustworthy and this thesis has not yet been published in any prior research or studies. Ho Chi Minh City, 27th January 2023 (Sign with full name) Vo Tran Minh Dinh i Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education ACKNOWLEDGEMENT Firstly, I would love to express my deepest gratitude to my instructor Assoc.
Pham Huy Tuan and other lecturers, Dr. Dang Quang Khoa and MS. Nguyen Van Khien, for their consistent support and for providing me with helpful recommendations and valuable counsel. Thanks to these words, I became a much more mature student.
I believe that the knowledge learned from those teachers helped me implement this bachelor’s thesis and reinforced my specialized knowledge, which will be invaluable for my not-too-distant future career. Moreover, I sincerely thank Dr. Tran Van Tron and MS. Dang Minh Phung for kindly allowing me to use the Die-sink EDM machine and measuring equipment.
I need their support to complete this project. Besides, I can never forget Mr. Le Nguyen Hoang Tan, a master’s student - inventor of the vibration module, who permitted me to use it – the soul of this project. He accompanies me at the start of the project and provides all of the necessary materials and assistance as I carry out the experiments.
Last but not least, big thanks and appreciation to my beloved peers and classmates for their recommendations, cooperation, encouragement, and constructive contributions to the accomplishment of this thesis from beginning to finish. Once again, thank you to all individuals who have gone through with me in this educational endeavor. Student Vo Tran Minh Dinh ii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education SUMMARY Project title: “A vibration-assisted electrical discharge machining tool to enhance the manufacturing process”. The main goals of this thesis are to assess the influence of vertical vibration along Z-axis generated by a compliant module and determine sets of technological parameters for each output parameters such as material removal rate, tool wear rate, and surface roughness.
The thesis covered the theoretical foundations of electrical discharge machining, vibration-assisted electrical discharge machining method, piezoelectricity, compliant mechanism, and Taguchi analysis. The author also mentioned about the design procedures of vibration module. The author examined four input parameters: Discharger current, Pulse-on time, Amplitude, and Frequency vibration. Some conclusions will be elaborated by applying the Taguchi analysis method and the data gained from experiments.
• Compared with normal EDM, Vibration-assisted EDM has some superiorities. On the one hand, vibration parameters positively impact the tool wear rate and surface roughness on both bottom and side surfaces. For example, the electrode wear rate was decreased by 17.5 %, and the surface finishes on the bottom and side surfaces were enhanced by 10% and 26%, respectively. On the other hand, the vibration parameters do not affect the material removal rate.
• Regarding the Tool wear rate, the optimal set of parameters are: I = 9A; 𝐓𝐨𝐧 = 60 s; A = 2.5 m; f = 1200 Hz • Regarding the Surface roughness on bottom surfaces, the optimal set of parameters are: I = 5A; 𝐓𝐨𝐧 = 30 s; A = 0.5 m; f = 100 Hz • Regarding the Surface roughness on bottom surfaces, the optimal set of parameters are: I = 5A; 𝐓𝐨𝐧 = 60 s; A = 1.5 m; f = 800 Hz • Regarding the Material removal rate, the optimal set of parameters are: I = 9A; 𝐓𝐨𝐧 = 60 s; A = 0.5 m; f = 100 Hz Ho Chi Minh City, 27th January 2023 (Sign with full name) Vo Tran Minh Dinh iii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education TABLE OF CONTENTS DISCLAIMER. iii TABLE OF CONTENTS. iv LIST OF ACRONYMS AND SYMBOLS. viii LIST OF FIGURES.
ix LIST OF TABLES .2 The needs of the topic.3 Scientific and practical significance .4 Research’s objectives and scopes .1 Introduction of Electrical Discharge Machining (EDM) .2 Classifications of EDM .3 Construction of Sink EDM machine:.6 Pros and cons .2 Introduction of Vibration-assisted machining. 10 iv Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education 2.2 Classifications of VAM .3 Introduction of Vibration-assisted Electrical Discharge Machining .4 Introduction of Piezoelectric .1 Classifications of Piezoelectric effect.5 Introduction of flexure hinges .2 Pros and cons .2 Taguchi method’s executing process .3 Advantages and disadvantages .4 Selection of orthogonal array matrix experiment. DESIGN OF VIBRATING TOOL (INHERITED) .3 Flexure hinge design.2 Optimizing the symmetric-zigzag flexure hinge.4 Design of other components .3 Electrical insulation components .5 Manufacturing and assembling the vibration module .6 Inspection of the vibration module. 36 v Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education 3.
EXPERIMENTAL PREPARATION AND IMPLEMENTATION .1 Sink-EDM machine .3 Surface roughness tester .2 Design of experiments .3 Design of experiment .3 Experimental implementation process .2 Experiment implementation process. COMPUTATION AND ANALYSIS OF EXPERIMENTAL DATA .1 Analysis of Material removal rate (MRR) .2 Vibration-assisted EDM (VAEDM) .2 Analysis of Tool wear rate (TWR) .2 Vibration-assisted EDM .3 Comparison of TWR between two machining schemes .3 Analysis of Surface roughness (SR) .2 Vibration-assisted EDM .3 Comparison of Surface roughness between two machining schemes. CONCLUSION AND DEVELOPMENT ORIENTATION. 73 vi Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education 6.
756 vii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education LIST OF ACRONYMS AND SYMBOLS EDM Electrical Discharge Machining EDM Micro Electrical Discharge Machining VAM Vibration-assisted Machining VAEDM Vibration-assisted Electrical Discharge Machining WEDM Wire Electrical Discharge Machining 𝑇𝑜𝑛 Pulse-on time 𝑇𝑜𝑓𝑓 Pulse-off time MRR Material Removal Rate TWR Tool Wear Rate SR Surface Roughness PEA Piezoelectric Actuator OA Orthogonal Array S/N Signal-to-Noise POM Polyoxymethylene DC Direct Current AC Alternating Current DOF Degree of Freedom DOE Design of Experiment viii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education LIST OF FIGURES Figure 2. Die-sink EDM. Hole drilling EDM. Effect of Vibration-assisted method on surface finish applied in milling operation.
1D and 2D “Elliptical” vibration cutting. Illustration for the mechanism of machining of vibration-assisted EDM .